Embodiments of the invention relate to methods and mechanisms to actuate components of downhole tools and, more specifically, downhole tools for oil, gas, geothermal, and horizontal drilling.
Actuating downhole tools disposed in a well-bore is often accomplished by dropping a ball down a bore of a drill string to break shear pins, which upon breaking frees a valve to open or actuate a downhole tool, such as a reamer. Once the shear pins are broken, the downhole tool and, consequently, the drill string must be removed from the well-bore to replace them. Other disadvantages, such as an inability to reset the actuating mechanism of the downhole tool while the downhole tool is still in the well-bore are inherent in this type of design.
In one aspect of the present invention, a downhole tool string component has at least a first end with an attachment to an adjacent tool string component and a second end spaced apart from the first end for attachment to another adjacent tool string component. The downhole tool string component includes a bore between the first end and the second end and a turbine disposed within the bore. An actuating assembly is arranged in the bore such that when actuated a clutch mechanically connects the actuating assembly to the turbine. When the actuating assembly is deactivated, the actuating assembly and turbine are mechanically disconnected.
The actuating assembly may move a linear translation mechanism, which may include a sleeve. The sleeve may have at least one port that is adapted to align with a channel formed in a wall of the bore when the sleeve moves. The actuating assembly may control a reamer, a stabilizer blade, a bladder, an in-line vibrator, an indenting member in a drill bit, or combinations thereof.
The actuating assembly may comprise a collar with a guide slot around a cam shaft with a pin or ball extending into the slot. When the collar moves axially, the cam rotates due to the interaction between the pin or ball and the slot. The cam shaft may be adapted to activate a switch plate, which is adapted to engage a plurality of gears. The actuating assembly may comprise at least one solenoid adapted to move a translation member in communication with a switching mechanism.
In some embodiments, the actuating assembly comprises a switching mechanism adapted to rotate a gear set in multiple directions.
The clutch may be a centrifugal clutch adapted to rotate with the turbine. The clutch may have at least one spring loaded contact adapted to connect the clutch to the shaft. The actuating assembly may be triggered by an increase in a velocity at which the turbine rotates, a decrease in the rotational velocity of the turbine, or a combination thereof. In some embodiments, the clutch may be controlled by a solenoid. The clutch may also be controlled over a wired drill pipe telemetry system, a closed loop system, or combinations thereof.
In another aspect of the present invention, a downhole tool string component has at least a first end with an attachment to an adjacent tool string component and a second end spaced apart from the first end for attachment to another adjacent tool string component. The downhole tool string component includes a bore between the first end and the second end and a turbine disposed within the bore. A turbine is disposed within the bore, the turbine being in mechanical communication with a linear actuator that is aligned with a central axis of the tool string component.
a is a perspective diagram of a portion of an embodiment of a tool string component that includes a reamer.
b is a cross-sectional diagram of the embodiment of the tool string component illustrated in
a is a close-up cross-sectional diagram of the portion of the embodiment of the downhole tool string component illustrated in
b is a close-up cross-sectional diagram of the portion of the embodiment of the downhole tool string component illustrated in
a is a cross-section of an embodiment of a downhole drill string component that includes a solenoid-activated clutch.
b is another cross-section view of the embodiment of a downhole drill string component that includes the solenoid-activated clutch illustrated in
a is a cross-section of an embodiment of a centrifugal clutch.
b is a perspective cut-away of the embodiment of the centrifugal clutch illustrated in
a is a cross-section diagram of an embodiment of a downhole drill string component that includes an actuation assembly.
b is a cross-section diagram of the embodiment of the downhole drill string component that includes the actuation assembly illustrated in
a is a cross-sectional diagram of an embodiment of a drill bit.
b is a cross-sectional diagram of another embodiment of a drill bit.
a is a perspective diagram of an embodiment of a plurality of blades of a turbine.
b is a perspective diagram of another embodiment of a plurality of blades of a turbine.
a is a perspective diagram of a portion of an embodiment of a downhole drill or tool string component 201 with a reamer 200. The reamer 200 may be adapted to extend into and retract away from a borehole wall. While against the borehole wall, the reamer 200 may be adapted to enlarge the diameter of the borehole larger than accomplished by the drill bit 104 at the front of the drilling assembly 103, as illustrated in
b is a cross-sectional diagram of the embodiment of the reamer 200 illustrated in
When the sleeve 202 is moved along direction A such that the ports 203 and openings 250 misalign, the dynamic force provided by the flowing drilling mud is cut off and the reamer 200 retracts. In other embodiments, a pause in drilling mud flow may also cause the reamer 200 to retract. The sleeve 202 may be moved to realign and misalign the ports 203 with the openings 250 on command to control the position of the reamer 200. In some embodiments, the ports 203 of the sleeve 202 is adapted to partially align with the openings 250, allowing a flow less than a flow through fully aligned ports 203 to engage the piston 205, thereby extending the reamer 200 less than its maximum radial extension. Further discussion and explanation of the mechanical structure and the process is made below in a discussion of
The turbine 400 is mechanically coupled to a shaft 412a at a proximal end 412b of the shaft 412a. The shaft 412a is mechanically coupled to a centrifugal clutch 502 at a distal end 412c of the shaft 412a. When drilling mud causes the turbine 400 to rotate, thereby rotating the shaft 412a, the centrifugal clutch 502 also rotates. Once the centrifugal clutch 502 rotates sufficiently fast, the centrifugal clutch 502 engages a mount 501, causing the mount 501 to rotate with the turbine 400. (The operation of the centrifugal clutch is discussed in further detail below and in reference to
The collar 503 may comprise a guide pin 557 that interacts with a guide slot 558 formed in a cam housing. When the collar 503 moves in an axial direction A′ it may rotate the cam 556. The rotation of the cam 556 may move a switch plate 504 adapted to selectively place the driving gear 410 in contact with a plurality of gears 304. When activated the plurality of gears 410 may transfer torque from the shaft 401a to a linear screw member 1004 (
The guide slot 558 may comprise a section that causes the collar 503 to move in a first direction and another section that causes the collar 503 to move in a second direction away from the first direction. The direction that the collar 503 travels dictates how the driving gear 410 engages the plurality of gears 304. In a preferred embodiment, the plurality of gears 304 is a planetary gear system that may control the direction that the gears within the planetary gear system rotate. A clockwise or counterclockwise rotation of the gears determines the forward or backward axial movement A of the linear screw member 1004, as illustrated in
As discussed above and in reference to
Referring now to
a, and in reference to
b discloses the ports 203 of the sleeve 202 aligned with the openings 250. In this instance, drilling mud is partially diverted along a path 602 through the openings 250 and into a channel 608 in which the piston 205 is disposed. The drilling mud engages the piston 205 as discussed above in reference to
a and 10b are cross-sectional diagrams disclosing an embodiment of a downhole tool component 201a that includes a solenoid activated clutch. A first solenoid 1002 and a second solenoids 1003 that acts in a direction opposite of the first solenoid 1002 are in mechanical communication with a translation member 1050 mechanically coupled to a shaft 1401. The shaft 1401 is coupled to and rotated by a turbine, such as turbine 400 in
The first solenoid 1002 and the second solenoid 1003 may be energized through either a local or remote power source. A telemetry system, such as provided by wired drill pipe or mud pulse, may provide an input for when to activate a solenoid. In some embodiments, a closed loop system may provide the input from a sensed downhole parameter and control the actuation.
a and 11b disclose an embodiment of a centrifugal clutch 1502, such as the centrifugal clutch 502 discussed above in association with
a and 12b disclose an embodiment of portion of a downhole drill string component 201b that includes an actuation assembly 1333 comprising a turbine 1400 connected to a shaft 1412. When a centrifugal clutch 1502a is engaged as described above in reference to
a is a cross-sectional diagram of an embodiment of a drill bit 104a. The drill bit 104a may comprise an actuating assembly 1500a patterned after those described above. The assembly 1500 may be adapted to axially move an indenting member 1501 towards a cutting surface 2000 of the drill bit 104a. The indenting member 1501 may be a steerable element, hammer element, penetration limiter, weight-on-bit controller, sensor, probe, or combinations thereof.
In the embodiment of a drill bit 104b illustrated in
a and 18b disclose an embodiment of a plurality of blades 2004a (
Whereas the present invention has been described in particular relation to the drawings attached hereto, it should be understood that other and further modifications apart from those shown or suggested herein, may be made within the scope and spirit of the present invention.
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