Earth-Boring Tool Actuator with Shape Memory Material

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Solution Overview

Problem

Conventional earth-boring tools face challenges in dynamically adjusting the position and exposure of cutting elements and bearing elements during drilling operations, limiting their effectiveness in varying formation conditions.

Innovation Solution

Incorporating shape memory materials into the actuators of earth-boring tools, which transform from a first shape to a second shape in response to a stimulus, allowing for adjustable positions of cutting elements and bearing elements, thereby enhancing the tool's adaptability to different formation conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional fixed-cutter earth-boring tools are used, then the structure is simple and reliable, but the cutting elements and bearing elements cannot be dynamically adjusted to adapt to varying formation conditions

Engineering Contradiction:

Improveadaptability to formation conditionsVSAvoidtool structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies the dynamics principle by transforming fixed, static cutting elements and bearing elements into movable, adjustable components. The actuator system enables dynamic repositioning of cutting elements along the blade and adjustment of bearing element positions, allowing the tool to adapt its configuration in real-time according to formation conditions encountered during drilling operations.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent replaces conventional mechanical adjustment mechanisms with a shape memory material-based actuator system. This substitution eliminates complex mechanical linkages, springs, and manual adjustment devices while achieving the same functional outcome through smart material response to thermal or electrical stimuli, thereby reducing overall device complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If the position of cutting elements is fixed, then the manufacturing and operation are simple, but the drilling efficiency decreases when formation hardness changes

Engineering Contradiction:

Improvedrilling efficiencyVSAvoidoperation simplicity

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The patent implements self-service through the actuator system that automatically adjusts cutting element positions based on formation conditions without requiring manual intervention. The shape memory material actuators respond autonomously to control signals, repositioning cutting elements to optimize drilling efficiency across varying formation hardness levels, thereby maintaining high productivity while simplifying operator workload.

Inventive Principle:

Principle #25Self-service

3Adaptability or versatility

If bearing elements are located entirely behind leading cutting elements, then the depth-of-cut is limited and formation damage is reduced, but the adaptability to different formation conditions is reduced

Engineering Contradiction:

Improveadaptability to formation conditionsVSAvoidformation damage

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies dynamics by enabling the bearing elements to transition from fixed positions behind cutting elements to adjustable positions that can be moved laterally and longitudinally. This dynamic positioning capability allows the bearing elements to maintain formation protection while adapting to different formation conditions, such as adjusting to prevent balling in soft formations or providing support in hard formations.

Inventive Principle:

Principle #15Dynamics

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 solution enables the earth-boring tools to dynamically adjust the depth-of-cut and exposure of cutting elements, improving drilling efficiency and reducing the need for frequent bit changes by allowing the tool to adapt to changes in formation hardness and type.

Implementation Method 1

The actuator includes at least one shape memory material configured to transform from a first shape to a second shape to change a position of at least one of a bearing pad or a cutting element coupled to the actuator with respect to the bit body in response to a stimulus. A transformation from the first shape to the second shape includes a phase change in the at least one shape memory material from a first solid phase to a second solid phase.

Methodology Applied

Scientific EffectShape memory material phase change: Phase Change

Data Source

PatentUS10487589B2Earth-boring tools, depth-of-cut limiters, and methods of forming or servicing a wellbore

Publication Date: 2019.11.26 BAKER HUGHES CO

AI summary

An earth-boring tool includes a bit body and an actuator coupled to the bit body. The actuator includes at least one shape memory material configured to transform from a first shape to a second shape to move a bearing pad or a cutting element with respect to the bit body in response to a stimulus. A transformation from the first shape to the second shape includes a phase change from a first solid phase to a second solid phase. A depth-of-cut limiter includes a bearing element and at least one shape memory material coupled to the bearing element. A method of forming or servicing a wellbore includes rotating an earth-boring tool within a wellbore, applying a stimulus to an actuator to convert at least one shape memory material from a first shape to a second shape, and continuing to rotate the earth-boring tool within the wellbore after applying the stimulus.