Superhard Bearing Assembly for Shaft Deflection Alignment

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Solution Overview

Problem

Conventional subterranean drilling systems experience axial misalignment of radial-bearing rotors with respect to stators due to repeated deflection of the output shaft, leading to decreased bearing performance or failure, particularly in subterranean drilling operations.

Innovation Solution

The use of bearing assemblies with superhard bearing elements featuring partial-ellipsoidal surfaces, where the superhard bearing surfaces are oriented at an oblique angle and distributed in rows around the central axis, allowing for improved contact and movement between opposing surfaces, thereby maintaining alignment and performance even when the rotor is tilted during drilling operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional radial-bearing assemblies use standard bearing elements with radial surfaces, then the bearing assembly provides basic support, but repeated shaft deflection causes axial misalignment between rotor and stator, leading to bearing failure

Engineering Contradiction:

Improvebearing performanceVSAvoidaxial alignment

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The bearing elements incorporate curved bearing surfaces with radii of curvature between 0.02 inches and 0.06 inches, allowing the surfaces to conform to each other during shaft deflection. This curvature enables the bearing elements to maintain contact and distribute loads evenly even when the shaft deflects axially, preventing misalignment-induced failure

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The invention changes the geometric parameters of the bearing elements by specifying precise radii of curvature for the bearing surfaces. This parameter modification allows the bearing elements to accommodate axial movement and deflection while maintaining proper contact and load distribution, thereby improving reliability under varying operational conditions

Inventive Principle:

Principle #35Parameter changes

2Strength

If bearing elements are attached to the rotor with superhard bearing surfaces oriented radially outward, then the bearing elements provide wear resistance, but shaft deflection causes uneven loading and axial displacement

Engineering Contradiction:

Improvewear resistanceVSAvoidloading uniformity

Core Design Contradiction:

StrengthVSForce

Solution Approach 1:

The bearing elements feature a differentiated structure with a superhard material layer (such as PCD or CBN) applied only to the bearing surface that contacts opposing elements, while the substrate provides structural support. This local application of superhard material maintains wear resistance at the contact interface while allowing the overall element to deform and accommodate deflection-induced loading variations

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The curved bearing surfaces with specific radii of curvature enable uniform load distribution across the contact area even during shaft deflection. The curvature allows the bearing surfaces to remain in contact and share loads evenly, preventing the uneven loading that would occur with flat or radially-oriented surfaces

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Adaptability or versatility

If the output shaft deflects at various angles during drilling operations, then the shaft can accommodate wellbore curvature, but the rotor becomes axially misaligned with the stator, causing bearing failure

Engineering Contradiction:

Improveshaft deflection capabilityVSAvoidbearing alignment

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The curved bearing surfaces are specifically designed with radii of curvature that match the expected deflection angles during drilling operations. This allows the rotor to deflect and follow wellbore curvature while the bearing elements maintain proper alignment and contact, preventing misalignment-induced failure

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The bearing elements are designed to dynamically accommodate shaft deflection through their curved geometry, allowing the rotor to move axially and angularly while maintaining bearing contact. This dynamic adaptability enables the bearing assembly to function reliably under varying operational conditions including shaft deflection

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS11536317B2Assemblies and apparatuses including superhard elements

Publication Date: 2022.12.27 US SYNTHETIC CORP

AI summary

Load-carrying apparatus, assemblies, and subterranean drilling systems may include a support ring with a plurality of contact elements coupled to the support ring. The plurality of contact elements may have a surface exhibiting a partially cylindrical shape.