Full-Metal Cycloid Downhole Motor Rolling Friction Rotor
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Solution Overview
Problem
Conventional downhole motors face issues with jamming, wear, and lack of high-temperature resistance due to rubber stators, processing inaccuracies, and interference fits between stator and rotor, especially when drilling with high-temperature fluids containing impurities.
Innovation Solution
A full-metal anti-high temperature cycloid downhole motor design featuring a rotor with copper rods that convert sliding friction to rolling friction, retractable for impurity passage, and a flow distribution mechanism that reduces friction resistance and increases inlet flow, utilizing full-metal materials for high-temperature resistance and improved service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a rubber stator is used in conventional screw motors, then the motor can operate, but it cannot be used under high temperature conditions (≥180°C)
Solution Approach 1:
The patent changes the material parameter of the stator from rubber to full-metal material, enabling the motor to withstand high temperatures (≥180°C) while maintaining structural integrity and operational reliability under extreme thermal conditions
Solution Approach 2:
The patent employs full-metal composite materials for both the stator and rotor, creating a high-temperature resistant structure that eliminates the thermal limitations of rubber-stator designs while ensuring durability in high-temperature drilling environments
2Temperature
If a full-metal screw replaces the rubber stator, then high temperature resistance is improved, but the processing accuracy cannot be guaranteed with current processing levels
Solution Approach 1:
The patent divides the rotor into multiple rotating heads with embedding slots, each containing rotor copper rods. This segmentation allows for modular manufacturing and assembly, making it feasible to achieve required precision through staged processing rather than requiring complete high-precision machining of the entire metal structure in one operation
Solution Approach 2:
The patent introduces embedding slots as intermediary structures that hold rotor copper rods. These slots serve as precision-guided features that can be manufactured with controlled tolerances, facilitating the assembly of precise metal-metad interfaces without requiring extremely difficult direct machining of the entire rotor-stator interface
3Length of moving object
If the screw motor uses spiral distribution with conventional lead, then the motor length is reduced, but the lead must be 2-3 times conventional lead to achieve flow distribution driving effect, making the motor too long
Solution Approach 1:
The patent employs asymmetric cycloid geometry in the rotor and stator design, where the rotating heads and embedding slots create an asymmetric flow distribution pattern. This asymmetric configuration enables effective flow distribution and driving action with a more compact lead distance, reducing the overall motor length while maintaining productivity
Solution Approach 2:
The patent transitions from conventional spiral distribution to a three-dimensional cycloid flow distribution mechanism involving rotating heads and embedding slots. This dimensional change in the flow path configuration enables more efficient fluid distribution within a shorter axial length, achieving the required driving effect with reduced motor length
4Device complexity
If the screw motor uses interference fit between stator and rotor, then the structure is compact, but drilling fluid containing impurities causes jam and abrasion, reducing service life
Solution Approach 1:
The patent replaces the static interference fit with a dynamic clearance fit between the rotor copper rods and stator grooves. This dynamic configuration allows the rotor to move freely within the stator, creating a clearance that prevents jamming by impurities while maintaining structural compactness through the precise clearance design
Solution Approach 2:
The patent converts the potential harm of impurities into a beneficial clearance mechanism. The embedding slots and rotor copper rod configuration create intentional clearances that allow impurities to pass through rather than cause jamming, transforming the harmful effect of contaminated drilling fluid into a non-issue while maintaining compact structure
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 solution significantly reduces friction resistance, wear, and kinetic energy loss, enhances service life by preventing jamming, and improves high-temperature resistance and torque output through rolling friction and efficient fluid flow management.
Implementation Method 1
the rotor copper rod partially protrudes from the notch under the centrifugal action and is in rolling engagement with the inner contour surface, so that the traditional sliding friction between the rotor and the stator is converted into rolling friction
Implementation Method 2
the rotor copper rod partially protrudes from the notch under the centrifugal action
Data Source
AI summary
A full-metal anti-high temperature cycloid downhole motor comprises an outer tube, a stator, a rotor, a partition plate, a flow distribution disc, and a flow guide mechanism. The inside of the stator is provided with N grooves, the inner side walls of the N grooves form an annular inner contour surface; the rotor is formed with N−1 rotating heads provided along the axial direction of the outer tube, and each rotating head is provided with an embedding slot, one side of the embedding slot is provided with a notch, a rotor copper rod that can be in rolling engagement with the inner contour surface through the notch is provided in the embedding slot, and there is a changing gap between the outer wall of the rotor copper rod and the inner wall of the embedding slot.