Downhole Drilling Tool with Multi-Port Flow Head
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Solution Overview
Problem
Existing downhole drilling technologies face challenges in efficiently managing drilling fluid flow to enhance drilling performance, particularly in preventing drill cuttings settlement and freeing stuck components during directional drilling.
Innovation Solution
A drilling tool with a motor-driven rotor-stator assembly and a multi-port flow head and restrictor system that creates a polyrhythmic pattern of pressure spikes by rotating ports, inducing eccentric motion and varying fluid flow to produce a percussive effect and axial movement in the drill string.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If drilling fluid flow is regulated to create vibrational and/or percussive effect, then drilling performance is improved, but drill cuttings may settle and components may become stuck
Solution Approach 1:
The patent employs periodic action by creating a polyrhythmic pattern of pressure spikes through the interaction between the rotating flow head with multiple ports and the stationary flow restrictor with multiple ports. This periodic variation in fluid flow generates vibrational and percussive effects that prevent drill cuttings settlement and free stuck components while maintaining improved drilling performance.
Solution Approach 2:
The patent applies mechanical vibration by designing a system where the rotating flow head and stationary flow restrictor create pressure spikes that induce vibrational and percussive effects in the drilling assembly. This vibration prevents drill cuttings from settling and frees stuck components, resolving the contradiction between improved drilling performance and prevention of cuttings settlement.
2Productivity
If drilling fluid flow is increased to improve drilling performance, then drilling efficiency is enhanced, but drag on the drill string increases
Solution Approach 1:
The patent uses periodic action to create a polyrhythmic pattern of pressure spikes that allows drilling fluid to be delivered in pulsing sequences. This periodic delivery improves drilling efficiency through enhanced rock fracture while the rhythmic nature of the flow reduces continuous drag on the drill string, allowing greater drilling distance with less exertion.
3Device complexity
If a simple flow restrictor is used to control drilling fluid flow, then device complexity is reduced, but ability to create polyrhythmic pressure patterns is limited
Solution Approach 1:
The patent applies segmentation by dividing the flow control function into two separate components: a rotating flow head with multiple ports and a stationary flow restrictor with multiple ports. This segmentation allows each component to be relatively simple in structure while their interaction creates the complex polyrhythmic pressure patterns needed for effective drilling, resolving the contradiction between device complexity and pressure pattern variability.
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
The tool improves drilling efficiency by preventing drill cuttings settlement, freeing stuck components, and reducing drag, allowing for greater drilling distance with less exertion, while minimizing interference with measurement while drilling equipment.
Implementation Method 1
A motor, such as a positive displacement motor or turbine driven assembly, is contained in the housing and includes a rotor-stator assembly in a multi-lobe arrangement, the motor for producing an eccentric motion of the rotor.
Implementation Method 2
An inverter is disposed along the drill string housing upstream from the motor and is capable of expanding and contracting the central cavity in response to fluid pressure changes produced by the drilling fluid flow.
Data Source
AI summary
A directional drilling tool includes a housing defining a central cavity for enabling the transmission of drilling fluid through the drill string. A motor contained in the housing includes a rotor-stator assembly, and produces eccentric motion of the rotor. An inverter or shock absorbing assembly disposed along the housing upstream from the motor functions to expend and contract the central cavity in response to fluid pressure changes produced by the drilling fluid flow. A valve assembly, comprising a multi-port flow head that rotates under influence of the motor and a multi-port flow restrictor, creates a varying pattern of pressure spikes in the drilling fluid as the ports of the flow head move into and out of alignment with the ports of the flow restrictor, which in turn induces a percussive effect and axial movement in the drill string.