Drill String Force Sensors for Multi-Tool Energy Management
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Solution Overview
Problem
Existing drilling technologies face challenges in efficiently managing forces and energy distribution among multiple rotary cutting tools in a drill string, particularly due to complex dynamic interactions and varying formation properties.
Innovation Solution
The implementation of strain gauges positioned above and below selected cutting structures in the drill string allows for the acquisition and analysis of force data, enabling the isolation of forces generated by individual cutting structures and optimizing drilling dynamics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple rotary cutting tools are used in a drill string, then drilling efficiency and capability are improved, but force distribution and energy management become complex and difficult to control
Solution Approach 1:
The patent segments the drill string into multiple sections, each equipped with independent force sensors that measure forces at specific locations. This segmentation allows individual monitoring of force distribution across different cutting tools, enabling precise control and optimization of each tool's performance while maintaining overall drilling efficiency.
Solution Approach 2:
The patent implements a feedback system where force sensors continuously monitor forces applied to multiple rotary cutting tools, and this data is fed back to a control system. The control system uses this feedback to dynamically adjust drilling parameters, optimize force distribution, and manage energy consumption, thereby resolving the complexity of controlling multiple cutting tools simultaneously.
2Measurement precision
If force sensors are installed on the drill string, then force measurement capability is improved, but device complexity and cost increase
Solution Approach 1:
Instead of installing a single complex force measurement system, the patent segments the measurement capability across multiple simpler force sensors positioned at strategic locations along the drill string. Each sensor provides localized force data, and collectively they deliver comprehensive force measurement capability with reduced individual sensor complexity and lower overall system cost.
Solution Approach 2:
The force sensors installed on the drill string serve multiple functions: they measure forces on individual cutting tools, monitor overall drill string behavior, provide data for real-time control, and enable post-drilling analysis. This multi-functionality justifies the added device complexity by delivering comprehensive measurement capabilities from a single sensor installation.
3Ease of operation
If real-time force data is collected and analyzed, then drilling control and optimization are improved, but data processing requirements and system complexity increase
Solution Approach 1:
The patent establishes a real-time feedback loop where force data collected by sensors is immediately processed and used to adjust drilling operations. This feedback mechanism simplifies drilling control by providing actionable insights in real-time, enabling operators to optimize performance without managing complex manual analysis procedures.
Solution Approach 2:
The drilling system incorporates automated data processing and analysis capabilities that operate autonomously, reducing the need for complex manual intervention. The system self-monitors force distribution, automatically identifies optimization opportunities, and implements control adjustments, thereby improving ease of operation while keeping the data processing system manageable through automation rather than human 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
This approach enhances drilling efficiency and tool design by allowing real-time dynamic control and post-drilling analysis of force data, leading to improved force distribution, energy management, and overall drilling performance.
Implementation Method 1
at least two force sensors positioned to obtain a force applied above the second contacting structure and a force applied below the second contacting structure
Data Source
AI summary
A drilling system, assembly, and method may help optimize drilling in a system that involves more than one rotary tool that engages the formation. A rotary tool may be a rotary cutting tool, such as a drill bit or reamer, or some other rotary tool (e.g. stabilizer or rotary steerable tool) that has the potential to drag on the wall of the hole being drilled and take energy away from cutting. In an example, a wellbore or portion thereof is formed by rotating a first rotary cutting tool having a first cutting structure in engagement with one portion of the formation together with a second rotary cutting tool having a second cutting structure in engagement with another portion of the formation. Forces are obtained above and below the second cutting structure. One or more drilling parameter or drill bit design parameter are adjusted in relation to a force differential between the forces above and below the second cutting structure.