National Technology & Engineering Solutions of Sandia, LLC

Other

Sandia Corporation

The United States of America As Represented by the Department of Energy

David W Raymond

Stephen Buerger

Jiann-Cherng Su

William T Radigan

Elton K Wright

Anirban Mazumdar

Steven James Spencer

Adam Foris

Timothy James Blada

Avery Ted Cashion, Iv

Mikhail Mesh

Mostafa Ahmed Elsayed

David A Glowka

A harmonic drive assembly and fluid-powered linear motors with both axial pistons are rotary piston arrangements incorporating the harmonic drive assembly are disclosed. The motors may be used in downhole drilling applications, but the drive assembly and/or motors may be used in other applications. The assembly, motors and methods use advanced harmonic drives, advanced helical drives, and combinations thereof with 1) motors with axial pistons and reciprocating linear rings to convert reciprocative axial motion to continuous rotary motion, and 2) motors with rotary pistons and reciprocating linear rings to rectify reciprocative rotary motion to continual rotary motion to improve performance over prior configurations. Axial pistons provide a robust simple solution for generating rotation; Rotational pistons provide increased torque generation as the torque generated is proportional to motor length. Since downhole drills are long, a high-torque motor can be produced using this method.

Systems and methods that use harmonic drives for converting reciprocating axial motion to continuous rotary motion, helical drives for converting reciprocating rotary motion to reciprocating axial motion and combinations thereof for converting reciprocating rotary motion to continuous rotary motion

A system or method for drilling includes autonomously controlling a rotary or percussive drilling process as it transitions through multiple materials with very different dynamics. The method determines a drilling medium based on real-time measurements and comparison to prior drilling data, and identifies the material type, drilling region, and approximately optimal setpoint based on data from at least one operating condition. The controller uses these setpoints initially to execute an optimal search to maximize performance by minimizing mechanical specific energy. Near-bit depth-of-cut estimations are performed using a machine learning prediction deployed in an embedded processor to provide high-speed ROP estimates. The sensing capability is coupled with a near-bit clutching mechanism to support drilling dysfunction mitigation.

Control systems and methods to enable autonomous drilling

A ball transfer mechanism for a harmonic drive and linear piston motor is disclosed. 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 in an exterior wall of a housing for converting rotary motion to linear motion, driving a linear piston motor. The harmonic drive drives a rotor of the linear piston motor. The harmonic drive includes a hollow cylindrical coupler portion engaging a rotor portion for transferring torque to the rotor portion. Transfer mechanisms disposed along a housing wall of the linear piston motor engage the coupler portion. The coupler portion includes harmonic cam grooves for receiving spherical balls in the ball transfer mechanism that drives rotational motion in the rotor in response to axially linear movement of the piston assembly.

Ball transfer mechanism with polycrystalline diamond bearing support

A fluid-powered linear motor with rotary pistons is disclosed. An application is for a downhole motor but it could be used in other applications. Rotational pistons provide increased torque generation as the torque generated is proportional to motor length. Since downhole drills are long (generally up to a maximum length of 30 ft.), a high-torque motor can be produced using this method. A pressurized fluid is used to drive the piston assemblies to produce bit shaft power. This concept employs rotary pistons and a mechanical rectifier to convert the rotational reciprocation produced by a reciprocating rotational piston into continuous rotary motion. Integration of synthetic diamond bearing assemblies into the motor allows for reduced friction and abrasive drilling fluid compatibility.

Fluid-powered linear motor with rotary pistons and motion rectifier and synthetic diamond bearing assemblies

Wind powered generator

A harmonic drive assembly and fluid-powered linear motors with both axial pistons are rotary piston arrangements incorporating the harmonic drive assembly are disclosed. The motors may be used in downhole drilling applications, but the drive assembly and/or motors may be used in other applications. The assembly, motors and methods use advanced harmonic drives, advanced helical drives, and combinations thereof with 1) motors with axial pistons and reciprocating linear rings to convert reciprocative axial motion to continuous rotary motion, and 2) motors with rotary pistons and reciprocating linear rings to rectify reciprocative rotary motion to continual rotary motion to improve performance over prior configurations.

A system or method for drilling includes autonomously controlling a rotary or percussive drilling process as it transitions through multiple materials with very different dynamics. The method determines a drilling medium based on real-time measurements and comparison to prior drilling data, and identifies the material type, drilling region, and approximately optimal setpoint based on data from at least one operating condition. The controller uses these setpoints initially to execute an optimal search to maximize performance by minimizing mechanical specific energy.

A fluid-powered linear motor with rotary pistons is disclosed. An application is for a downhole motor but it could be used in other applications. Rotational pistons provide increased torque generation as the torque generated is proportional to motor length. Since downhole drills are long (generally up to a maximum length of 30 ft.), a high-torque motor can be produced using this method. A pressurized fluid is used to drive the piston assemblies to produce bit shaft power. This concept employs rotary pistons and a mechanical rectifier to convert the rotational reciprocation produced by a reciprocating rotational piston into continuous rotary motion.

Fluid-powered linear motor with rotary pistons and motion rectifier

A suppression module, a suppression assembly, and a drilling tool are disclosed. The suppression module includes a spindle having a first end and a second end, an ear plate slideably disposed between the first end and the second end, a spring positioned between the ear plate and the first end, and an activation mechanism coaxially disposed around the second end of the spindle. The activation mechanism engages the ear plate, activating the spring, or disengages the ear plate, deactivating the spring. The suppression assembly includes at least two suppression modules in series coupled to a processor. The suppression modules are activated or deactivated by the processor, each of the suppression modules being activated or deactivated independent of the other suppression modules. The drilling tool includes a drill pipe, a drill bit, a vibration sensor, and a suppression assembly between the drill pipe and the drill bit.

Variable rate compliance modules, assemblies and tools for suppression of drilling vibrations

A modular motor is disclosed that includes a piston/harmonic drive assembly that is axially cycled. The piston/harmonic drive assembly is coupled to a ball transfer arrangement that converts the axial motion into rotary motion to rotate a rotor that can be used to rotate a drill bit.

Modular fluid powered linear piston motors with harmonic coupling

Self-assembling segmented coiled tubing is a concept that allows the strength of thick-wall rigid pipe, and the flexibility of thin-wall tubing, to be realized in a single design. The primary use is for a drillstring tubular, but it has potential for other applications requiring transmission of mechanical loads (forces and torques) through an initially coiled tubular. The concept uses a spring-loaded spherical 'ball-and-socket' type joint to interconnect two or more short, rigid segments of pipe. Use of an optional snap ring allows the joint to be permanently made, in a 'self-assembling' manner.

Self-assembling segmented coiled tubing

A motor is disclosed that includes a module assembly including a piston that is axially cycled. The piston axial motion is coupled to torque couplers that convert the axial motion into rotary motion. The torque couplers are coupled to a rotor to rotate the rotor.

Growing community of inventors

Edgewood, NM, United States of America

David W Raymond