Surface-Contact Constant-Velocity Joint for High-Torque Wellbore Coupling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing wellbore operations face limitations in transferring high levels of torque due to inefficient coupling mechanisms, leading to decreased efficiency and increased costs.
Innovation Solution
A constant-velocity joint with surface contact forks that maintains consistent surface engagement throughout movement, allowing for significant torque transfer between coupled components by using a yoke and adaptors with grooves and guide surfaces, enabling conversion of eccentric to concentric rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional coupling mechanisms are used to transfer torque between components, then the device structure remains simple, but the torque transfer capability is limited
Solution Approach 1:
The coupling mechanism is divided into multiple segments including a first component, a second component, and a constant velocity joint connecting them. This segmentation allows each component to be optimized for specific functions while collectively achieving high torque transfer capability through distributed load paths
Solution Approach 2:
The constant velocity joint incorporates spherical elements and curved surfaces to enable smooth rotation and torque transfer between misaligned components. The spherical geometry maintains consistent contact surfaces during rotation, allowing high torque transfer while accommodating angular deviations between connected components
2Productivity
If conventional coupling mechanisms are used, then the device structure remains simple, but the efficiency of downhole operations decreases
Solution Approach 1:
The constant velocity joint is pre-configured with optimized geometry and surface characteristics before deployment. The spherical elements and contact surfaces are precisely formed during manufacturing to ensure optimal torque transfer and minimal friction from the outset, improving operational efficiency without requiring complex adjustment mechanisms
Solution Approach 2:
The spherical geometry of the constant velocity joint enables smooth, continuous rotation with consistent mechanical advantage throughout the rotation cycle. This curved surface design maintains optimal contact conditions during eccentric motion, maximizing torque transfer efficiency and reducing energy losses in downhole operations
3Force
If coupling mechanisms with limited torque capacity are used, then the device structure remains simple, but increased costs result from decreased operational efficiency
Solution Approach 1:
The coupling mechanism is divided into multiple segments including a first component, a second component, and a constant velocity joint connecting them. This segmentation allows each component to be optimized for specific functions while collectively achieving high torque transfer capability through distributed load paths
Solution Approach 2:
The design utilizes specific geometric parameters of the spherical elements and contact surfaces to optimize torque transfer. By carefully selecting curvature radii, contact surface areas, and material properties, the joint achieves high torque capacity while remaining manufacturable using standard machining processes
Data Source
AI summary
A constant-velocity joint can have three pieces: a yoke, a first adaptor, and a second adaptor. Grooves on opposite sides of the yoke can receive forks of the adaptors and be perpendicular to one another. The yoke can have a guide surface within each groove so that a matching following surface on the fork of the adaptor can engage the guide surface to guide the movement of the fork within the groove. The adaptors may pivot within the grooves such that surfaces of flanks of the forks remain engaged or provide a consistent amount of surface contact with flanks of the groove throughout the pivot of the forks. Torque can be transferred through the engaged flanks as the joint is used to convert eccentric rotation to concentric rotation.