Stationary Thrust Bearing Alignment via Spherical Interlocking
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Solution Overview
Problem
Thrust bearings in well systems can become misaligned due to downhole pressures and loads, significantly reducing their thrust load carrying capacity, with a one-degree misalignment potentially reducing capacity by over 60%.
Innovation Solution
The use of an assembly that includes a stationary thrust bearing with an interlocking component and a flexible member to maintain alignment, where the interlocking component is positioned to prevent rotation about the central axis while allowing rotation in two degrees of freedom, and the flexible member counteracts rotational forces to return the bearing to a default aligned position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If thrust bearings are used in downhole drilling operations, then they can support high thrust loads, but they become misaligned due to downhole pressures and loads, significantly reducing their thrust load carrying capacity
Solution Approach 1:
The patent applies the dynamics principle by allowing the stationary thrust bearing to rotate about two perpendicular axes (pitch and roll) through spherical interlocking components, enabling the bearing to dynamically adjust and maintain alignment with the rotating thrust bearing despite downhole pressures and loads. This dynamic adaptability resolves the contradiction by preserving alignment stability while maintaining high thrust load carrying capacity.
Solution Approach 2:
The patent changes the degrees of freedom parameter of the stationary thrust bearing, allowing rotation about two axes rather than being completely fixed. This parameter change enables the bearing to adapt to alignment variations caused by downhole conditions, resolving the contradiction between supporting high thrust loads and maintaining alignment stability.
2Stability of the object's composition
If the stationary thrust bearing is completely fixed to prevent any rotation, then alignment is maintained, but the bearing cannot accommodate downhole pressure variations and load changes
Solution Approach 1:
The stationary thrust bearing is designed with selective mobility through spherical interlocking components that allow rotation about two perpendicular axes while preventing rotation about the central axis. This dynamic design enables the bearing to accommodate downhole pressure variations and load changes while maintaining proper alignment, resolving the contradiction between alignment stability and adaptability to downhole conditions.
Solution Approach 2:
The bearing support structure is segmented into multiple independent spherical interlocking components, each allowing rotation about perpendicular axes. This segmentation enables independent adjustment in multiple degrees of freedom, providing adaptability to various downhole conditions while maintaining overall alignment stability.
3Adaptability or versatility
If the stationary thrust bearing is allowed to rotate freely about all axes, then adaptability to downhole conditions is maximized, but alignment is lost and thrust load carrying capacity is reduced
Solution Approach 1:
The stationary thrust bearing is designed with controlled dynamics, allowing rotation about two perpendicular axes (pitch and roll) through spherical interlocking components while preventing rotation about the central axis. This selective dynamic freedom provides adaptability to downhole conditions while maintaining alignment and preserving high thrust load carrying capacity, resolving the contradiction between adaptability and force capacity.
Solution Approach 2:
The interlocking component design creates asymmetric constraints, allowing rotation about two axes while preventing rotation about the third axis (central axis). This asymmetric freedom of movement enables adaptability to downhole conditions without compromising alignment or thrust load carrying capacity.
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 solution effectively maintains the alignment of thrust bearings, thereby significantly enhancing their thrust load carrying capacity and preventing the substantial reduction seen with misalignment.
Implementation Method 1
a flexible member positioned within the thrust bearing sleeve and adjacent to the stationary thrust bearing for opposing a rotational force about the one or more axes applied to the stationary thrust bearing by another thrust bearing
Data Source
AI summary
An assembly for use in a wellbore can include a drill string having an outer housing and a thrust bearing sleeve positioned within the outer housing of the drill string. The assembly can also include a stationary thrust bearing positioned within the thrust bearing sleeve and coaxially around a mandrel extending through a longitudinal length of the thrust bearing sleeve. The assembly can further include an interlocking component including a first end coupled to the stationary thrust bearing and a second end positioned in a recessed portion of a housing of the drill string for preventing the stationary thrust bearing from rotating about a central axis of the mandrel, and for allowing the stationary thrust bearing to rotate about one or more axes perpendicular to the central axis. The assembly can include a flexible member for opposing a rotational force applied to the stationary thrust bearing by another thrust bearing.