Downhole Motor Stator Fabrication Using Bonding Agent and Reinforcing Material
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Solution Overview
Problem
Downhole motors in drilling operations face reduced useful life due to particulate matter in drilling fluid, necessitating cost-effective manufacturing and quick replacement of motor components.
Innovation Solution
A method for fabricating a stator for downhole motors involving a stator tube with a bonding agent, a mandrel, and a reinforcing material, where the reinforcing material is solidified to bond with the stator tube's interior surface, and the mandrel is removed, using materials like iron, steel, and polymers, to create a stator with a helical cavity and internal lobes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional stator manufacturing methods are used, then manufacturing cost is reduced, but the stator durability and longevity are compromised due to reduced resistance against particulate matter damage
Solution Approach 1:
The stator is constructed using a composite structure combining a stator tube (metal or polymer) with a stator insert (reinforcing material). This composite approach provides enhanced durability and resistance against particulate matter damage while maintaining manufacturability through modular assembly processes.
Solution Approach 2:
The stator is divided into separate components: a stator tube and a stator insert. The stator insert can be manufactured independently using various reinforcing materials, then assembled into the stator tube. This segmentation allows for optimized manufacturing of each component while improving overall durability.
2Duration of action of stationary object
If stators are manufactured with enhanced durability features, then service life is extended, but manufacturing cost increases
Solution Approach 1:
The invention allows selection of different materials and configurations based on operational requirements. The stator tube can be made from metal or polymer, and the stator insert can be made from various reinforcing materials, enabling parameter optimization to balance cost and service life extension.
Solution Approach 2:
The modular design with separable stator tube and stator insert allows for cost-effective replacement of only the worn insert component rather than the entire stator assembly, reducing overall manufacturing costs while extending service life through targeted replacement.
3Productivity
If quick replacement of motor components is enabled, then operational efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The stator is segmented into a stator tube and a stator insert that can be manufactured and replaced independently. This segmentation enables quick replacement of the insert component in the field, improving productivity while allowing for standardized precision manufacturing of modular components.
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
The method enhances the durability and longevity of downhole motor stators by providing a robust and long-lasting component that can withstand the harsh drilling environment, reducing maintenance costs and improving operational efficiency.
Implementation Method 1
applying a bonding agent to the interior surface of the stator tube... the reinforcing material is solidified to bond the reinforcing material to the interior surface of the stator tube
Implementation Method 2
when solidifying the reinforcing material to bond the reinforcing material to the interior surface of the stator tube various techniques may be utilized. These techniques may include, but are not limited to the use of heat curing
Implementation Method 3
the mandrel may be coated with a release agent having numerous forms including a solid, semi-solid or a liquid
Data Source
AI summary
The present invention recites a method of fabricating a stator for a downhole motor, the method comprising the steps of providing a stator tube having an interior surface and applying a bonding agent to the interior surface of the stator tube. Additionally, a mandrel is positioned within the stator tube, the mandrel having an outer geometry that is complimentary to a desired inner geometry for the stator. Furthermore, a reinforcing material is introduced into the stator tube to fill space between the mandrel and the interior surface of the stator tube and subsequently solidified to bond the reinforcing material to the interior surface of the stator tube. The mandrel is then removed from the bonded stator tube and reinforcing material such that a stator is fabricated.