Downhole Tool Support Structure for Extendable Element Wear

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Solution Overview

Problem

Downhole tools with extendable elements face wear and degradation due to tangential forces and bending moments when engaging formation material during reaming operations, leading to reduced tool life and increased costs.

Innovation Solution

The design incorporates a support structure with a mating surface that bears tangential forces on the extendable elements, reducing the load on the tool body and extending its service life by providing additional support, allowing for easy replacement of worn components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If extendable elements are used to engage formation material, then reaming capability is improved, but wear and degradation of the tool body increases

Engineering Contradiction:

Improvereaming capabilityVSAvoidtool body durability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The tool body is segmented into functional components: the main tool body structure and replaceable support structures. The support structures are detachably coupled to the tool body, allowing them to be separated and replaced independently when worn, while the main tool body remains intact and reusable.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support structures are designed as consumable, replaceable components that bear the brunt of wear from tangential forces. When these support structures become worn or degraded, they can be quickly replaced in the field, while the expensive main tool body is preserved for continued use.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Productivity

If extendable elements contact formation material, then reaming function is achieved, but tangential forces cause bending moments that degrade the tool body

Engineering Contradiction:

Improvereaming functionVSAvoidtool body structural integrity

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The support structures serve as intermediary components between the extendable elements and the main tool body. They absorb and bear the tangential forces and bending moments generated during reaming, protecting the main tool body from direct exposure to these degrading forces.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If the tool body structure supports extendable elements directly, then structural simplicity is maintained, but wear on the tool body increases

Engineering Contradiction:

Improvestructural simplicityVSAvoidtool body wear resistance

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The support for extendable elements is segmented into separate, detachable support structures rather than being integral to the tool body. This allows the support structures to be replaced when worn without replacing the entire tool body.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support structures are designed to be discarded when worn and recovered (replaced) in the field. This allows the main tool body to be recovered and reused multiple times, reducing overall operational costs.

Inventive Principle:

Principle #34Discarding and recovering

4Ease of repair

If support structures are made replaceable, then maintenance speed is improved, but device complexity increases

Engineering Contradiction:

Improvemaintenance speedVSAvoidsupport structure configuration

Core Design Contradiction:

Ease of repairVSDevice complexity

Solution Approach 1:

The support structures are segmented as separate, modular components that can be independently removed and replaced. This segmentation enables quick field replacement without requiring complex disassembly of the entire tool.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support structures are designed with universal coupling mechanisms that allow them to be attached to and removed from the tool body in a standardized manner, simplifying the replacement process and enabling quick maintenance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11421478B2Support features for extendable elements of a downhole tool body, tool bodies having such support features and related methods

Publication Date: 2022.08.23 BAKER HUGHES CO

AI summary

An earth-boring tool includes a tool body configured to rotate in a wellbore and carrying at least one extendable element. The at least one extendable element is configured to move between a retracted position and an extended position projecting radially beyond the tool body. The at least one extendable element has a mating surface. The earth-boring tool includes a support structure located in the tool body and having a support surface that is located and configured to face the mating surface of the at least one extendable element when the at least one extendable element is in the extended position. The support surface of the support structure is configured to bear at least a portion of the tangential forces acting on the extendable element during rotation of the earth-boring tool in the wellbore when the at least one extendable element is in the extended position.