Tilting Superhard Bearing Elements for Downhole Motors
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Solution Overview
Problem
Existing bearing systems in subterranean drilling and mechanical applications face challenges with wear resistance and efficiency due to the limitations of traditional materials, particularly in large-scale applications where superhard materials like polycrystalline diamond compacts (PDCs) are restricted by size and production constraints.
Innovation Solution
The use of individual superhard bearing elements with tilting features, such as pivot mechanisms, allows for the assembly of multiple superhard segments to form a continuous bearing surface, enabling the creation of larger tilting pads with enhanced wear resistance and efficiency, even beyond the size limitations of single PDCs, by utilizing materials like polycrystalline diamond and tungsten carbide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fixed-position PDC bearing elements are used, then the bearing structure is simple and easy to manufacture, but the wear resistance and operational life are limited
Solution Approach 1:
The bearing elements are designed to tilt dynamically in response to load conditions rather than remaining fixed in position. Each superhard bearing element can rotate about a tilt axis, allowing the bearing surface to self-adjust its orientation to optimize load distribution and minimize wear during operation.
Solution Approach 2:
The bearing assembly is divided into multiple discrete superhard bearing elements distributed circumferentially around the axis, each capable of independent tilting motion. This segmentation allows each element to adapt locally to load variations while maintaining overall bearing functionality.
2Force
If larger bearing elements are used to increase load capacity, then the wear resistance improves, but the production constraints of superhard materials limit the size
Solution Approach 1:
Instead of manufacturing one large superhard bearing element, the system uses multiple smaller superhard elements that can be produced within existing manufacturing constraints. These segments are arranged circumferentially to collectively support larger loads, effectively scaling up load capacity without exceeding production limits for individual elements.
Solution Approach 2:
Multiple smaller superhard bearing elements are combined in a circumferential arrangement to achieve the load-bearing capacity of a larger element. The collective action of all segments provides the necessary load support while each individual segment remains within manufacturable size limits.
3Reliability
If multiple superhard segments are assembled to form larger bearing surfaces, then the wear resistance increases, but the device complexity increases
Solution Approach 1:
Each superhard bearing element is designed with universal features including a standardized tilt mechanism, bearing surface, and mounting interface. This universality allows identical components to be assembled in different configurations and positions, simplifying the overall assembly process despite using multiple elements.
Solution Approach 2:
The tilting capability of each element provides dynamic adaptability that compensates for minor variations in assembly tolerances. The self-adjusting nature of the bearing elements reduces the stringency of assembly precision requirements, thereby managing complexity.
4Productivity
If tilting features are added to superhard bearing elements, then the efficiency and wear resistance improve, but the manufacturing complexity increases
Solution Approach 1:
The tilting feature introduces dynamic motion capability to the bearing elements, allowing them to self-adjust during operation. This dynamic adaptation improves efficiency by optimizing the bearing surface contact and load distribution, while the pivot mechanism is designed to be relatively simple in construction.
Solution Approach 2:
The tilting bearing elements automatically adjust their orientation in response to applied loads without external control or adjustment mechanisms. The self-service nature of this adaptation improves bearing efficiency and wear characteristics while avoiding the complexity of active control systems.
Data Source
AI summary
Embodiments relate to tilting superhard bearing element bearing assemblies and apparatuses. The disclosed assemblies/apparatuses may be employed in downhole motors of a subterranean drilling system or other mechanical systems. In an embodiment, a bearing assembly may include a support ring and a plurality of superhard bearing elements each of which is tilted and/or tiltably secured relative to the support ring and distributed circumferentially about an axis. Each of the superhard bearing elements includes a bearing surface and a base portion. The base portion of the at least one of the superhard bearing elements may include a tilting feature configured to allow the at least one of the superhard bearing elements to be tiltable about a tilt axis. The bearing assembly includes retaining features that secure the superhard bearing elements to the support ring.