Replaceable Spline Insert for Downhole Tool Repair
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Solution Overview
Problem
Existing downhole tools with expandable cutter blocks face challenges in maintaining efficiency and longevity due to spline damage during wellbore expansion, leading to tools being classified as 'damaged beyond repair', necessitating the need for innovative solutions to extend tool life and facilitate repair or replacement of damaged components.
Innovation Solution
The implementation of modular, replaceable spline inserts with splines that can be re-faced or replaced, allowing for continued tool functionality by engaging with corresponding splines on the tool's body, enabling radial expansion and retraction of cutter blocks, and allowing for the repair or replacement of damaged components without discarding the entire tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If spline inserts are made integral to the tool body, then structural strength is improved, but repairability deteriorates
Solution Approach 1:
The spline is divided into two separate components: an integral portion on the tool body and a removable insert portion. The insert portion can be detached and replaced when damaged, while the integral portion remains permanently attached to the tool body. This segmentation allows the tool to maintain structural strength through the integral connection while enabling repairability by replacing only the damaged insert portion rather than the entire tool.
2Reliability
If the entire tool is discarded when splines are damaged, then reliability is maintained, but loss of substance increases
Solution Approach 1:
The removable insert portion is extracted as a separate replaceable component from the tool body. When spline damage occurs, only the damaged insert portion is removed and discarded, while the main tool body with its integral spline portion is retained and reused. This extraction principle prevents the waste of the entire tool by isolating and replacing only the specific damaged component.
Solution Approach 2:
The damaged insert portion is discarded while the tool body and integral spline portion are recovered and reused. The design enables selective disposal of only the worn or damaged insert component, allowing the majority of the tool to be recovered and continue service, thereby reducing overall material waste while maintaining tool reliability.
3Ease of repair
If modular inserts are implemented, then ease of repair is improved, but device complexity increases
Solution Approach 1:
The spline is segmented into an integral portion and a removable insert portion that can be independently replaced. This segmentation improves ease of repair by allowing the insert to be detached and replaced without affecting the tool body, while the complexity increase is minimized by keeping the segmentation simple and the connection mechanism straightforward.
Data Source
AI summary
An expandable tool includes a body and a recess extending at least partially through the body from an outer radial surface of the body. A spline insert may be at least partially positioned in the recess and coupled to the body. The spline insert may include a single spline or multiple splines. A cutter block or other expandable member may be at least partially positioned in the recess. The cutter block or other expandable member may include a spline on a side surface thereof, which spline may be engaged with the one or more splines of the spline insert. Engagement between one or more splines of the spline insert and spline of the cutter block or other expandable member may allow the expandable member to move radially outward from a retracted position to an expanded position, and vice versa.