Patent Grant
10968700
The present invention relates to the field of drilling, and specifically to a ball transfer assembly for a high temperature downhole motor.
Downhole drills are used for oil drilling, geothermal drilling, and other deep earth penetration applications. Downhole drills include rotary and percussive drills. For nearly any drilling method, rotational energy must be transferred downhole in order to promote rock reduction. The drill bit may be rotated by an electric motor or fluid/hydraulic system. The rotating action can be produced either at the surface or near the drill bit. In addition to rotational cutting, drills may also be pressurized or mechanically actuated to force the drill bit to hammer against the rock/earth. Prior art rotation systems and methods are complex, require large form factors to create sufficient torque, and require a high degree of maintenance.
The most common method of downhole energy transfer is rigid drill pipe. The drill pipe is rotated from the surface, with drilling joints added for tripping (moving in and out of the hole). For this type of system, the entire drill string rotates. Typically a rotary table system or a top drive is used to drive the drill string. Although it is well suited for vertical drilling, it has limited applications in directional drilling because the drill string curvature and thrust loads generate additional torque that the surface based motor must overcome and drill pipe survive.
Downhole techniques used to generate rotation such as positive displacement motors (PDMs) are limited in their temperature range due to the use of elastomers. Energy resources like geothermal and deep oil and gas wells lie in hot (160° C.-300° C.), and often hard rock. The high-temperatures limit the use of PDM's in those environments. In addition, PDMs generate rotation by eccentric motion of the rotor around the motor case which induces significant lateral vibration to the drilling assembly.
U.S. Pat. No. 9,447,798 discloses a motor that includes a module assembly incorporating an axially-cycled piston. The piston axial motion is torque coupled to convert the axial motion into rotary motion. The method does not require elastomers for operation and the rotor operates concentrically thereby not inducing lateral vibration. A modular fluid powered linear piston motor with harmonic coupling is described in U.S. patent application Ser. No. 15/090,282 filed Apr. 4, 2016, entitled “Modular Fluid Powered Linear Piston Motors with Harmonic Coupling”, and includes a drive train to convert reciprocating motion from a piston into rotary motion in an output shaft. Rotation is accomplished with roller balls captured between an inner race and a drive liner to facilitate rotation between a rotor and a stator. These roller balls must operate with low friction to enable smooth operation of the motor. Additionally, they must operate under a high contact load as they are in the preloaded and active load path to transmit torque to the output rotor. Finally, they must potentially operate with an abrasive drilling fluid under the rigors of high ambient temperatures and high friction conditions.
What is needed is a system and/or method that satisfies one or more of these needs or provides other advantageous features. Other features and advantages will be made apparent from the present specification. The teachings disclosed extend to those embodiments that fall within the scope of the claims, regardless of whether they accomplish one or more of the aforementioned needs.
One embodiment relates to a ball transfer mechanism. The ball transfer mechanism includes a spherical ball and a cylindrical seat portion. The seat portion defines a hemispherical shaped recess with a contour for receiving the ball. The ball transfer mechanism is disposed within an exterior wall of a hollow cylindrical housing for converting rotary motion to linear motion, driving a linear piston motor disposed within the housing.
Another embodiment relates to a harmonic drive member for driving a rotor of a linear piston motor. The harmonic drive member includes a hollow cylindrical coupler portion engaging a rotor portion for transferring torque to the rotor portion. Ball transfer mechanisms disposed along a housing wall of the linear piston motor are engageable with the coupler portion. The coupler portion includes harmonic cam grooves for receiving spherical balls in the ball transfer mechanism. A mutual reaction between the ball transfer mechanisms and the harmonic cam grooves drives axially linear movement of the drive portion and generates a torque to rotate the rotor portion.
A further embodiment relates to a linear piston motor for drilling. The linear piston motor includes a rotor portion axially positioned within a housing portion. The rotor portion includes pistons in sealed engagement with an inner wall of the housing. The pistons apply hydraulic pressure in a linear direction of flow. A harmonic drive is positioned axially within the housing. The harmonic drive has a hollow cylindrical coupler portion engaging the rotor portion for transferring torque to the rotor portion, and ball transfer mechanisms engageable with the respective coupler portion.
One advantage is a drilling system configured with a ball transfer device against which the rotor may react. The harmonic drive and piston interaction is provided by a ball transfer apparatus in a ball support. A tungsten carbide supported polycrystalline diamond (PCD) bearing is created, wherein the ball transfer resides within the diamond seat.
Another advantage is that friction between diamond and steel is low (i.e., friction coefficient of 0.1). Hence, the ball in the ball transfer rotates easily on the diamond seat.
Another advantage is that operational forces are carried via contact loads between the ball transfer, the ball, and the coupler having preferred values of elasticity and compressive strength. Hence, a tungsten carbide ball or comparable material can be used as the ball transfer for improved performance for this application.
A further advantage of the disclosed ball transfer apparatus is, since the ball may rotate in any required direction, rolling contact exists between the ball and the harmonic drive. Therefore, with rolling contact the ball transfer does not wear as fast.
Alternative exemplary embodiments relate to other features and combinations of features as may be generally recited in the claims.
The application will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements, in which:
Before turning to the figures which illustrate the exemplary embodiments in detail, it should be understood that the application is not limited to the details or methodology set forth in the following description or illustrated in the figures. It should also be understood that the phraseology and terminology employed herein is for the purpose of description only and should not be regarded as limiting.
Referring to
A pressure chamber 34 is formed between piston 22 and cylinder wall 24. A pressurized fluid 17 may enter the pressure chamber and be available to be discharged outside of the rotor housing through pressure ports and collected through exhaust ports into an exhaust chamber to be exhausted from the rotor housing 18.
Referring next to
In one embodiment, the ball transfer unit 36 may be made from PCD dies, wherein the PCD is a synthetic material produced by sintering diamond powder in the presence of a metal catalyst under extreme heat and pressure to fuse the diamond particles together. With a diamond seat 42, 44, the ball rotates easily with reduced friction. In an alternate embodiment, a spherical bearing 60 constructed of individual polycrystalline diamond inserts 62 (See
While the exemplary embodiments illustrated in the figures and described herein are presently preferred, it should be understood that these embodiments are offered by way of example only. Accordingly, the present application is not limited to a particular embodiment, but extends to various modifications that nevertheless fall within the scope of the appended claims. The order or sequence of any processes or method steps may be varied or re-sequenced according to alternative embodiments.
It is important to note that the construction and arrangement of the ball transfer with PCD bearing support, as shown in the various exemplary embodiments is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. Accordingly, all such modifications are intended to be included within the scope of the present application. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. In the claims, any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the exemplary embodiments without departing from the scope of the present application.
This invention was developed under Contract No. DE-NA0003525 between the United State Department of Energy and National Technology & Engineering Solutions of Sandia, LLC, for the operation of the Sandia National Laboratories.
| Number | Name | Date | Kind |
|---|---|---|---|
| 5396965 | Hall | Mar 1995 | A |
| 10100850 | Raymond | Oct 2018 | B1 |
| 20090236387 | Simonelli | Sep 2009 | A1 |
| 20120132453 | Fu | May 2012 | A1 |
| 20190107127 | Raymond | Apr 2019 | A1 |
| 20190128391 | Raymond | May 2019 | A1 |
