PDC Bearing Attachment Using Hybrid Coupling for Harsh Loads
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Solution Overview
Problem
Conventional bearing apparatuses face challenges in maintaining the integrity and longevity of bearing elements due to harsh environments and substantial forces, leading to premature failure and increased maintenance and replacement costs.
Innovation Solution
The proposed bearing assemblies utilize multiple modes of coupling between bearing elements and base members, including mechanical fasteners, clamped structures, geometrical fits, welding, and brazing, to enhance the attachment and durability of bearing elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If brazing is used to couple bearing elements to bearing rings, then the bearing elements can be securely attached, but the manufacturing complexity increases and premature failure occurs due to harsh environments and substantial forces
Solution Approach 1:
The bearing element is divided into two distinct parts: a reusable bearing insert and a sacrificial bonding layer. The bonding layer is applied only to the mounting surface of the bearing ring, while the bearing insert remains separate until installation. This segmentation allows the bearing insert to be replaced without replacing the entire bearing assembly, reducing manufacturing complexity and cost while maintaining attachment strength through the bonding layer.
Solution Approach 2:
The bonding layer is designed as a sacrificial, disposable component that remains attached to the bearing ring after the bearing insert is removed. This sacrificial layer eliminates the need for complex re-brazing or re-welding operations during maintenance, simplifying the repair process and reducing manufacturing complexity while maintaining secure attachment during service.
2Strength
If conventional brazing is used to attach bearing elements, then secure attachment is achieved, but repair and replacement become time-consuming and costly
Solution Approach 1:
The bearing element is segmented into a reusable insert and a sacrificial bonding layer on the bearing ring. This allows the insert to be quickly removed and replaced without disturbing the bonding layer or requiring complex re-attachment procedures, significantly reducing maintenance time while maintaining secure attachment strength during operation.
Solution Approach 2:
The bonding layer is designed as a disposable sacrificial component that remains on the bearing ring after insert removal. This eliminates the need for time-consuming re-brazing or re-welding operations during maintenance, reducing maintenance time and cost while preserving attachment strength for the next insert installation.
3Strength
If brazing is used to couple bearing elements to bearing rings, then attachment is achieved, but the process causes premature failure in harsh environments
Solution Approach 1:
The bearing element is segmented into a reusable insert and a sacrificial bonding layer. The bonding layer is designed to remain attached to the bearing ring while the insert can be replaced. This segmentation protects the critical bearing insert from thermal damage during attachment, improving reliability and in-service life in harsh environments while maintaining secure attachment strength.
Solution Approach 2:
The bonding layer serves as a sacrificial protective barrier that absorbs thermal and mechanical stresses during installation and service. This sacrificial layer protects the bearing insert from damage, extending its in-service life and improving reliability in harsh downhole environments while maintaining secure attachment.
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 approach extends the in-service life of bearing elements and assemblies, reduces maintenance and replacement costs, and simplifies the manufacturing process by allowing for the use of lower temperature welding techniques and various materials.
Implementation Method 1
The at least one bearing element includes a carrier element attached to the substrate, the carrier element including a threaded opening formed therein. Additionally, the mechanical fastener extends through the opening in the base member and is threadedly coupled with the carrier member.
Implementation Method 2
The at least two includes a mechanical fastener and either welding or brazing.
Implementation Method 3
The at least two includes a mechanical fastener and either welding or brazing.
Data Source
AI summary
Bearing assemblies and methods of manufacturing bearing assemblies are provided in the present disclosure. In one embodiment, a bearing assembly includes a base member and at least one bearing element coupled to the base member. The bearing element may be coupled with the base member by at least two different coupling techniques, including two of: a mechanical fastener, a clamped structure, a geometrical fit, welding, and brazing. In one embodiment, a first technique may include use of a mechanical fastener and a second technique may include welding or brazing. In another embodiment, a first technique may include use of a clamping mechanism or structure and a second technique may include welding or brazing. In another embodiment, a first technique may include use of a geometrical fit and a second technique may include welding or brazing.