Superhard Bearing Assembly for Shaft Misalignment in Drilling

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Solution Overview

Problem

Conventional radial-bearing assemblies in subterranean drilling systems experience axial misalignment due to repeated deflection of the output shaft, leading to decreased bearing performance or failure, as the superhard bearing elements are not designed to accommodate angular misalignment effectively.

Innovation Solution

The bearing assemblies incorporate superhard bearing elements with partial-ellipsoidal surfaces that are oriented at an oblique angle and distributed in rows around the central axis, allowing for rotational freedom and maintaining contact between opposing surfaces even when the inner and outer bearing assemblies are tilted relative to each other, thus preventing axial misalignment and ensuring continuous operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional radial-bearing assemblies use superhard bearing elements with flat or cylindrical surfaces, then manufacturing is simplified, but axial misalignment occurs due to repeated deflection of the output shaft, leading to decreased bearing performance or failure

Engineering Contradiction:

Improvebearing performanceVSAvoidbearing element geometry

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies spheroidality by configuring the superhard bearing elements with curved, spherical, or partial-spherical bearing surfaces instead of flat or cylindrical surfaces. This curvature allows the bearing elements to accommodate angular misalignment and deflection of the output shaft, maintaining reliable contact between bearing surfaces while improving durability and performance under varying operational conditions.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Adaptability or versatility

If superhard bearing elements are oriented at an oblique angle and distributed in rows, then rotational freedom and contact maintenance are improved, but device complexity increases

Engineering Contradiction:

Improverotational freedomVSAvoidbearing element configuration

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies segmentation by dividing the bearing assembly into multiple superhard bearing elements distributed in rows around the central axis, with each element oriented at an oblique angle. This segmentation allows individual elements to accommodate rotational movement and maintain contact independently, providing adaptability to varying operational conditions while distributing mechanical stresses across multiple elements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies asymmetry by orienting the superhard bearing elements at oblique angles relative to the central axis rather than symmetrically perpendicular to it. This asymmetric orientation enables the bearing elements to accommodate angular misalignment and deflection, maintaining reliable contact between opposing bearing surfaces during rotational operation and improving adaptability to varying operational conditions.

Inventive Principle:

Principle #4Asymmetry

3Duration of action of stationary object

If the bearing elements are designed to accommodate angular misalignment, then bearing durability is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvebearing durabilityVSAvoidsurface geometry precision

Core Design Contradiction:

Duration of action of stationary objectVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentUS10995795B2Bearing assemblies and apparatuses including superhard bearing elements

Publication Date: 2021.05.04 US SYNTHETIC CORP

AI summary

A bearing assembly includes a support ring circumferentially surrounding a central bearing axis and a plurality of superhard bearing elements coupled to the support ring. Each of the plurality of superhard bearing elements has a base, a superhard bearing surface, and a lateral periphery extending between the base and the superhard bearing surface. The superhard bearing surface has a partial-ellipsoidal surface shape. A bearing apparatus includes an inner bearing assembly and an outer bearing assembly. A subterranean drilling system includes an output shaft operably coupled to a bearing apparatus.