Segmented Drill String Manufacturing via Layer Fusing
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Solution Overview
Problem
Existing manufacturing techniques for downhole tool components in drill strings face challenges with high machining costs and complexity due to the need for precise tolerances and the discarding of partially completed sections, leading to waste and inefficiency.
Innovation Solution
The method involves constructing segments from a plurality of layers using incremental construction techniques, allowing for incremental monitoring of design tolerances and re-manufacturing of partially assembled segments, with layers being sliced perpendicular to the axial direction and fused together using metal joining processes like electron beam welding, enabling complex internal features and reducing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional subtractive manufacturing techniques are used to manufacture downhole tool components, then manufacturing precision can be achieved through sophisticated equipment, but machining costs increase and waste is generated due to discarding partially completed sections
Solution Approach 1:
The downhole tool component is divided into multiple discrete sections that can be manufactured separately using additive manufacturing. Each section can be independently produced and then assembled, eliminating the need to discard entire components when a defect is found in one area. This segmentation allows for localized re-manufacturing rather than complete component rejection.
Solution Approach 2:
The patent implements incremental monitoring of design tolerances during the additive manufacturing process, allowing for real-time detection and correction of deviations. This preliminary action prevents the accumulation of errors that would otherwise require discarding the entire component, enabling continuous manufacturing with maintained precision.
2Manufacturing precision
If traditional manufacturing techniques are used with strict tolerance requirements, then design tolerance faults can be detected, but partially completed portions must be discarded leading to waste
Solution Approach 1:
By dividing the component into multiple buildable sections with intermediate connection features, the patent enables selective re-manufacturing of only defective sections. This segmentation transforms a monolithic component into modular units, reducing material waste when defects are detected during incremental monitoring.
Solution Approach 2:
The patent recovers value from partially completed components by enabling re-manufacturing of specific sections rather than discarding the entire component. The modular design with connection features allows defective sections to be replaced while retaining functional sections, effectively recovering material and reducing waste.
3Shape
If complex internal bore features are formed through sophisticated equipment, then conduit routing requirements can be met, but manufacturing complexity and cost increase
Solution Approach 1:
The patent divides complex internal bore features into multiple simpler segments that can be formed in separate additive manufacturing steps. Each section contains simplified conduit pathways that are easier to manufacture, and the complex overall geometry is achieved through assembly of these segmented sections rather than forming the entire complex geometry in one operation.
Solution Approach 2:
The patent utilizes the build dimension of additive manufacturing to create complex internal features that would be difficult to achieve with traditional subtractive methods. By building up geometry layer by layer, the patent can form complex conduit pathways and internal structures more simply than by removing material, reducing manufacturing equipment complexity requirements.
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 reduces machining costs, minimizes waste, and allows for easier embedding and inspection of components during assembly, resulting in lower component density and improved reliability, with segments being manufactured for replacement rather than repair.
Implementation Method 1
The layers may then be joined together using a metal joining process such as electron beam welding
Data Source
AI summary
A method is provided for manufacturing a segment of a drill string, such as a tubular tool, from a plurality of layers. The method includes arranging a plurality of layers based on a selected length of the segment. Each of the plurality of layers includes an aperture that is received over an alignment feature that restricts movement of the plurality of layers to two or fewer degrees of freedom. A joining process is performed to join the plurality of layers, which may include at least one replacement layer.