Drill Whirl Detection via Dual-Axis Acceleration Analysis
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Solution Overview
Problem
Drilling assemblies and drill bits often experience whirl, a type of dysfunction that can lead to failures and damage, and existing methods lack effective means to accurately determine the whirl rate and its direction and magnitude in real-time during drilling operations.
Innovation Solution
The method involves obtaining measurements of acceleration along two orthogonal axes using sensors and processing these data to calculate whirl rates in both the time and frequency domains, determining the presence, direction, and magnitude of whirl by comparing these rates against predefined criteria, and utilizing a processor to implement this analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are used to measure whirl parameters in real-time, then detection reliability is improved, but device complexity increases
Solution Approach 1:
The measurement system is segmented into multiple independent sensors (acceleration sensor, rotational speed sensor, torque sensor) that can be deployed separately at different locations along the drill string. Each sensor measures a specific parameter, and the data is processed independently before being combined for whirl detection, reducing the complexity of any single sensor while maintaining comprehensive detection capability
Solution Approach 2:
A processor acts as an intermediary between the sensors and the whirl detection algorithm. The processor receives raw data from multiple sensors, performs coordinate transformations, and processes the data through mathematical models to determine whirl parameters. This intermediary approach separates the sensing function from the analysis function, allowing for more reliable detection without requiring complex integrated sensors
2Measurement precision
If multiple sensors are deployed to measure whirl accurately, then measurement precision is improved, but device complexity increases
Solution Approach 1:
Data from multiple sensors (acceleration, rotational speed, torque) is merged and combined through coordinate transformations and mathematical processing to calculate comprehensive whirl parameters. The system combines measurements from different sensor types and locations to achieve precise three-dimensional whirl characterization, achieving high measurement precision through data fusion rather than requiring complex individual sensors
Solution Approach 2:
The system transforms measurements from multiple spatial dimensions and sensor types into a unified coordinate system to determine whirl parameters. By converting acceleration data from three orthogonal directions and combining it with rotational speed and torque measurements, the system achieves precise measurement of whirl rate, direction, and magnitude through dimensional transformation rather than requiring complex single-point sensors
3Loss of time
If real-time processing of sensor data is performed, then response time is improved, but computational requirements increase
Solution Approach 1:
The system performs preliminary processing of sensor data by continuously monitoring and pre-processing measurements from acceleration, rotational speed, and torque sensors. Basic transformations and data preparation are performed in advance as data streams in, so that when whirl conditions are detected, the processed information is immediately available for rapid response. This preliminary action reduces the computational burden during critical whirl events while maintaining real-time response capability
Data Source
AI summary
In one aspect, a method of determining the presence of whirl for a rotating tool is disclosed that in one embodiment includes obtaining measurements (ax) of a parameter relating to the whirl of the tool along a first axis and measurements (ay) of the parameter along a second axis of the tool, determining a first whirl in a time domain for the tool using ax and ay measurements, determining a second whirl rate for the tool in a frequency domain from ax and ay measurements and determining the presence of the whirl from the first whirl rate and second whirl rate. The method further quantifies the whirl of the tool from the first and second whirl rates.