Torque Measurement with MEMS Shear Stress Sensors

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Solution Overview

Problem

Excessive torque applied to drill strings in well drilling and other contexts, such as narrow well diameters or borehole cave-ins, is not effectively measured or addressed by existing technologies.

Innovation Solution

A torque measurement tool using multiple concentric shafts with a flexible coupling and a MEMS shear stress sensor to measure shear stress, which calculates torque based on the displacement and stress experienced by the flexible coupling, allowing for real-time torque monitoring and adjustment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional torque measurement methods are used in drilling operations, then the drilling process can continue, but excessive torque from narrow well diameters or borehole cave-ins cannot be accurately detected

Engineering Contradiction:

Improvetorque measurement accuracyVSAvoidexcessive torque damage

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces traditional mechanical torque measurement methods with a MEMS-based shear stress sensor that uses microelectromechanical systems to detect shear stress on the drill string, enabling precise torque measurement in challenging drilling conditions

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the measurement parameter from direct torque measurement to shear stress measurement, using the relationship between shear stress and torque to indirectly but accurately determine torque values, which allows for detection of excessive torque conditions

Inventive Principle:

Principle #35Parameter changes

2Productivity

If the drill string is rotated at high speed to maintain productivity, then drilling efficiency improves, but torque fluctuations from wellbore deformities increase

Engineering Contradiction:

Improvedrilling efficiencyVSAvoiddrill string stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent implements a feedback system where the MEMS shear stress sensor continuously monitors torque during drilling operations, and the system uses this real-time data to detect anomalies caused by wellbore deformities, enabling operators to adjust drilling parameters to maintain both productivity and reliability

Inventive Principle:

Principle #23Feedback

3Measurement precision

If real-time torque monitoring is implemented using advanced sensors, then wellbore structural deformities can be detected, but the device complexity increases

Engineering Contradiction:

Improvetorque detection capabilityVSAvoidsensor system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent extracts the torque measurement function from complex mechanical measurement systems and implements it using a compact MEMS shear stress sensor, reducing the overall device complexity while maintaining or improving measurement precision

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the measurement approach to use shear stress as the primary parameter, which can be measured by simpler MEMS sensors compared to direct torque measurement systems, thereby reducing device complexity while achieving accurate torque detection

Inventive Principle:

Principle #35Parameter changes

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

Enables accurate measurement and real-time analysis of torque, facilitating the identification and mitigation of structural deformities in wellbore walls, such as narrow-well conditions or cave-ins, improving drilling efficiency and safety.

Implementation Method 1

the flexible coupling experiences shear stress, since it couples to both concentric shafts

Methodology Applied

Scientific EffectShear stress: Shear Stress

Implementation Method 2

a flexible coupling, such as silicone rubber, positioned between the concentric shafts

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 3

A MEMS shear stress sensor is mounted on a surface of either of the multiple concentric shafts that faces the flexible coupling

Methodology Applied

Scientific EffectPiezoresistive effect: Piezoresistive Effect

Data Source

PatentUS10920570B2Measurement of torque with shear stress sensors

Publication Date: 2021.02.16 HALLIBURTON ENERGY SERVICES INC

AI summary

A torque measurement tool and method of use is presented which comprises a first outer shaft extending along a longitudinal axis and containing a second inner shaft positioned within the first outer shaft and extending along the longitudinal axis, A flexible coupling is positioned between the first outer shaft and the second inner shaft. A shear stress sensor is positioned within the second inner shaft, is exposed to the first outer shaft and contacts the flexible coupling.