Thrust Bearing Radius Optimization for Radial Reaction Force Reduction
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Solution Overview
Problem
The efficiency and reliability of thrust bearings in well tools are compromised due to unacceptable radial reaction forces caused by bending moments and deflections during drilling operations, which can lead to damage to the wellbore and other components.
Innovation Solution
A method is introduced to determine the optimal radius of the thrust bearing interface between convex and concave surfaces using computational devices, based on geometric and material properties, to minimize radial reaction forces by selecting a radius that corresponds to the lowest determined reaction force, thereby reducing the risk of bearing failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the thrust bearing geometry is designed with a standard radius, then the manufacturing is simplified, but the radial reaction force increases causing bearing failure and damage to wellbore
Solution Approach 1:
The patent applies parameter changes by optimizing the radius of the thrust bearing interface from a standard value to a specifically calculated value (R = 0.953 inches). This parameter modification reduces the radial reaction force on the bearing surfaces, preventing bearing failure while maintaining manufacturing feasibility. The optimization balances manufacturing simplicity with improved bearing reliability under drilling loads.
2Reliability
If the thrust bearing radius is optimized to minimize radial reaction force, then the bearing reliability improves, but the manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by performing computational optimization of the thrust bearing radius during the design phase. Using finite element analysis and iterative calculations, the optimal radius (R = 0.953 inches) is determined before manufacturing. This preliminary computational work eliminates the need for complex manufacturing processes, as the optimized geometry can be produced using standard manufacturing methods while achieving reduced radial reaction forces and improved bearing reliability.
3Strength
If the thrust bearing operates under high radial reaction force, then the structural integrity is maintained, but the bearing efficiency decreases and damage occurs
Solution Approach 1:
The patent applies parameter changes by modifying the thrust bearing interface radius to optimize the distribution of radial reaction forces. The optimized radius (R = 0.953 inches) reduces peak stresses and improves load distribution across the bearing surfaces, thereby maintaining structural integrity while enhancing bearing efficiency and preventing damage during drilling operations.
Data Source
AI summary
A method and apparatus according to which the optimal radius of a thrust bearing in a well tool is determined. In one embodiment, the method includes receiving inputs representing a plurality of geometric characteristics and material properties of the well tool, the well tool including a housing, a shaft extending within the housing, and the thrust bearing, which includes convex and concave surfaces that define an interface having a radius; determining, based on the inputs, an expected value of the bending moment of the well tool in the vicinity of the thrust bearing; determining, based on the expected value of the bending moment, one or more expected values of the radial reaction force at the interface, which values depend upon the radius of the interface; and selecting, based on the one or more expected values of the radial reaction force, an optimal radius of the interface.