3D Drill Bit Dull Grading for Accurate Wear and Life Prediction
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Solution Overview
Problem
Drill bit grading is subjective, time-consuming, and prone to human error, leading to inefficiencies in determining the condition and useful life of drill bits due to variations in human judgment and limited visual assessment.
Innovation Solution
Utilizing time-of-flight imaging and machine learning to create a digital model of drill bits, enabling accurate evaluation of cutter conditions and predicting remaining life through a portable electronic device and computing system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual dull grading by engineers is used, then human judgment and visual assessment can be applied, but the process is subjective, time-consuming, and prone to human error
Solution Approach 1:
The patent replaces the manual mechanical visual inspection process with an automated optical imaging system using time-of-flight cameras and machine learning algorithms. The system captures depth images and color images of the drill bit, processes them through AI models to identify cutters and assess their condition, thereby eliminating human subjectivity and time consumption while maintaining or improving grading accuracy.
Solution Approach 2:
The patent creates a digital replica or copy of the drill bit by capturing its physical characteristics through time-of-flight and color imaging. This digital model serves as a copy that can be analyzed computationally, allowing multiple assessments without repeatedly exposing the actual drill bit to human inspectors, thus saving time and improving consistency.
2Reliability
If manual dull grading is performed, then field engineers can assess drill bit condition, but results vary between individuals and are susceptible to subjective biases
Solution Approach 1:
The patent replaces the human engineer's subjective visual assessment with an automated computer-based system that uses time-of-flight imaging and machine learning. This substitution eliminates inter-individual variability and subjective biases, providing consistent and reliable grading results. The system complexity increases but is justified by the significant improvement in reliability and consistency of the grading process.
3Measurement precision
If traditional visual inspection methods are used, then simple equipment can be employed, but the assessment is limited by human vision capabilities
Solution Approach 1:
The patent transitions from two-dimensional visual inspection to three-dimensional assessment by incorporating time-of-flight depth imaging. This adds a depth dimension to the imaging system, enabling the detection of subtle topographical changes on cutter surfaces that are imperceptible to the human eye. The enhanced detection capability comes with increased system complexity, but the additional dimensional information significantly improves measurement precision.
Solution Approach 2:
The patent replaces human visual capabilities with electronic imaging sensors that have superior detection limits. The time-of-flight camera and color camera system can detect features at the micrometer scale, far beyond human visual acuity. This substitution of biological vision with electronic sensing systems dramatically enhances detection capability while accepting the corresponding increase in device complexity.
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
Provides objective and efficient dull grading by accurately assessing drill bit wear and predicting remaining life, reducing downtime and resource consumption.
Implementation Method 1
depth data from a time-of-flight camera
Data Source
AI summary
Embodiments of the invention relate to automatically dull grading drill bits and portions thereof based on three-dimensional digital models made from one or more images of the drill bits taken at a drilling site by an electronic device with a time-of-flight camera, wherein a method for evaluating drill bits at a site of a drilling rig is disclosed. The method includes receiving, from a requestor, a plurality of images of a drill bit that has been used, at least some of the plurality of images including time-of-flight images that have been captured by an electronic device (e.g., a computing device, an electronic device, etc.) on-site at or near a drill rig. The method includes generating a digital model of the drill bit based on the plurality of images.