INTEGRATED BEARING SECTION AND METHOD

• US 20190330922A1
• Filed: 04/27/2018
• Published: 10/31/2019
• Est. Priority Date: 04/27/2018
• Status: Active Grant

• Current Assignee: Rival Downhole Tools, LC
• Original Assignee: Rival Downhole Tools, LC
• Inventors: von Gynz-Rekowski, Gunther HH, Reeves, Mark Allen, Herben, William Christian
• Granted Patent: US 10,851,589 B2
• Time in Patent Office: Days
• CPC Class Codes: E21B 4/003 Bearing, sealing, lubricating details for roller bits E21B10/22

Abstract

An integrated bearing section includes a mandrel partially disposed within a housing. The bearing section includes spherical members disposed between the mandrel'"'"'s outer surface and the housing'"'"'s inner surface. A radial bearing portion is formed by spherical members disposed partially within grooves and engaging a flat profile opposing surface. The grooves may be in the mandrel'"'"'s outer surface, an outer surface of a mandrel sleeve, the housing'"'"'s inner surface, or an outer radial bearing'"'"'s inner surface. The flat profile opposing surface may be on an outer radial bearing'"'"'s inner surface, the housing'"'"'s inner surface, the mandrel'"'"'s outer surface, or a mandrel sleeve'"'"'s outer surface. A thrust bearing portion is formed by spherical members disposed partially within grooves in two opposing surfaces, such as the mandrel'"'"'s outer surface or a mandrel sleeve'"'"'s outer surface, and the housing'"'"'s inner surface or an outer thrust bearing'"'"'s inner surface.

Claims

1. An integrated bearing section for a mud lubricated drilling motor, comprising:

a housing with a housing inner bore;

a mandrel at least partially disposed within the housing inner bore, the mandrel including an outer surface having a series of circumferential grooves;

a plurality of spherical members, wherein each of the spherical members is disposed partially within one of the circumferential grooves of the mandrel;

an outer radial bearing disposed around the mandrel and within the housing inner bore, the outer radial bearing including a flat profile inner surface, wherein at least one of the spherical members engages the flat profile inner surface of the outer radial bearing for allowing relative axial movement between the mandrel and the outer radial bearing; and

an outer thrust bearing disposed around the mandrel and within the housing inner bore, the outer thrust bearing including an inner surface having a circumferential groove, wherein at least one of the spherical members engages the circumferential groove of the outer thrust bearing.

2. The integrated bearing section of claim 1, wherein the inner surface of the outer radial bearing includes a shoulder configured to limit relative axial movement between the outer radial bearing and the mandrel.

3. The integrated bearing section of claim 1, wherein the outer thrust bearing is formed of two semi-cylindrical members.

4. The integrated bearing section of claim 1, wherein the outer thrust bearing is formed of a series of rings.

5. The integrated bearing section of claim 1, further comprising a second outer radial bearing disposed around the mandrel and within the housing inner bore, the second outer radial bearing including a flat profile inner surface, wherein at least one of the spherical members engages the flat profile inner surface of the second outer radial bearing for allowing relative axial movement between the mandrel and the second outer radial bearing, and wherein the outer thrust bearing is disposed between the outer radial bearing and the second outer radial bearing.

6. The integrated bearing section of claim 5, further comprising a nut member disposed around the mandrel and threadedly engaging an end of the housing, wherein the nut member includes a flat profile inner surface, and wherein at least one of the spherical members engages the flat profile inner surface of the nut member for allowing relative axial movement between the mandrel and the nut member.

7. The integrated bearing section of claim 1, wherein all spherical members have the same radius.

8. An integrated bearing section for a mud lubricated drilling motor, comprising:

a housing with a housing inner bore;

a mandrel at least partially disposed within the housing inner bore, the mandrel including a restricted diameter section;

a mandrel sleeve disposed around the restricted diameter section of the mandrel and within the housing inner bore, wherein the mandrel sleeve includes an outer surface having a series of circumferential grooves;

a plurality of spherical members, wherein each of the spherical members is disposed partially within one of the circumferential grooves of the mandrel sleeve;

an outer radial bearing disposed around the mandrel sleeve and within the housing inner bore, the outer radial bearing including a flat profile inner surface, wherein at least one of the spherical members engages the flat profile inner surface of the outer radial bearing for allowing relative axial movement between the mandrel sleeve and the outer radial bearing; and

an outer thrust bearing disposed around the mandrel sleeve and within the housing inner bore, the outer thrust bearing including an inner surface having a circumferential groove, wherein at least one of the spherical members engages the circumferential groove of the outer thrust bearing.

9. The integrated bearing section of claim 8, wherein the mandrel sleeve is formed of two semi-cylindrical members.

10. The integrated bearing section of claim 8, wherein the mandrel sleeve is formed of a single cylindrical sleeve.

11. The integrated bearing section of claim 8, wherein the mandrel sleeve is formed of two or more cylindrical sleeves disposed around the mandrel axially adjacent to one another.

12. The integrated bearing section of claim 11, wherein the mandrel sleeve is formed of a first mandrel sleeve disposed within the outer radial bearing, a second mandrel sleeve disposed within the outer thrust bearing, and a third mandrel sleeve disposed within a lower housing section of the housing;

wherein the lower housing section includes a flat profile inner surface; and

wherein at least one of the spherical members is partially disposed within one of the circumferential grooves in the third mandrel sleeve and engaging the flat profile inner surface of the lower housing section for allowing relative axial movement between the third mandrel sleeve and the housing.

13. The integrated bearing section of claim 8, wherein the outer radial bearing and the outer thrust bearing are integrally formed.

14. The integrated bearing section of claim 8, wherein all spherical members have the same radius.

15. The integrated bearing section of claim 8, wherein the inner surface of the outer radial bearing includes a shoulder configured to limit relative axial movement between the outer radial bearing and the mandrel sleeve.

16. The integrated bearing section of claim 8, wherein the outer thrust bearing is formed of two semi-cylindrical members.

17. The integrated bearing section of claim 8, wherein the outer thrust bearing is formed of a series of rings.

18. The integrated bearing section of claim 8, further comprising a second outer radial bearing disposed around the mandrel sleeve and within the housing inner bore, the second outer radial bearing including a flat profile inner surface, wherein at least one of the spherical members engages the flat profile inner surface of the second outer radial bearing for allowing relative axial movement between the mandrel sleeve and the second outer radial bearing, and wherein the outer thrust bearing is disposed between the outer radial bearing and the second outer radial bearing.

19. The integrated bearing section of claim 18, wherein the outer radial bearing, the second radial bearing, and the outer thrust bearing are integrally formed.

20. The integrated bearing section of claim 8, further comprising a nut member disposed around the mandrel and threadedly engaging a lower end of the housing, wherein the nut member includes a flat profile inner surface, and wherein at least one of the spherical members engages the flat profile inner surface of the nut member for allowing relative axial movement between the mandrel sleeve and the nut member.

21. An integrated bearing section for a mud lubricated drilling motor, comprising:

a housing with a housing inner bore, wherein an inner surface of the housing inner bore includes a circumferential groove;

a mandrel at least partially disposed within the housing inner bore, the mandrel including a first mandrel section and a second mandrel section, wherein the first mandrel section includes a flat profile outer surface and the second mandrel section includes an outer surface having a circumferential groove, wherein the circumferential groove in the inner surface of the housing inner bore is axially aligned with the flat profile outer surface of the first mandrel section;

an outer thrust bearing disposed around the second mandrel section and within the housing inner bore, the outer thrust bearing including an inner surface having a circumferential groove in axial alignment with the circumferential groove in the outer surface of the second mandrel section; and

a plurality of spherical members, wherein at least one of the spherical members is disposed partially within the circumferential groove of the second mandrel section and disposed partially within the circumferential groove of the outer thrust bearing, and wherein at least one of the spherical members is disposed partially within the circumferential groove of the housing inner bore and engaging the flat profile outer surface of the first mandrel section for allowing relative axial movement between the mandrel and the housing.

22. The integrated bearing section of claim 21, further comprising:

a lower housing threadedly engaging a lower end of the housing, the lower housing including a lower housing inner bore with an inner surface including a circumferential groove;

wherein the mandrel further includes a third mandrel section disposed within the lower housing inner bore, wherein the third mandrel section includes a flat profile outer surface, wherein the circumferential groove in the inner surface of the lower housing inner bore is axially aligned with the flat profile outer surface of the third mandrel section; and

wherein at least one of the spherical members is disposed partially within the circumferential groove of the lower housing inner bore and engaging the flat profile outer surface of the third mandrel section for allowing relative axial movement between the mandrel and the lower housing.

23. The integrated bearing section of claim 21, wherein the outer thrust bearing is formed of two semi-cylindrical members.

24. The integrated bearing section of claim 21, wherein the outer thrust bearing is formed of a series of rings.

25. An integrated bearing section for a mud lubricated drilling motor, comprising:

a housing with a housing inner bore, wherein an inner surface of the housing inner bore includes a circumferential groove;

a mandrel at least partially disposed within the housing inner bore, the mandrel including a restricted diameter section;

a first mandrel sleeve and a second mandrel sleeve disposed around the restricted diameter section of the mandrel and within the housing inner bore, wherein the first mandrel sleeve includes a flat profile outer surface, wherein the circumferential groove in the inner surface of the housing inner bore is axially aligned with the flat profile outer surface of the first mandrel sleeve, wherein the second mandrel sleeve includes an outer surface having a circumferential groove;

an outer thrust bearing disposed around the second mandrel sleeve and within the housing inner bore, the outer thrust bearing including an inner surface having a circumferential groove in axial alignment with the circumferential groove in the outer surface of the second mandrel sleeve;

a plurality of spherical members, wherein at least one of the spherical members is disposed partially within the circumferential groove of the second mandrel sleeve and disposed partially within the circumferential groove of the outer thrust bearing, and wherein at least one of the spherical members is disposed partially within the circumferential groove of the housing inner bore and engaging the flat profile outer surface of the first mandrel sleeve for allowing relative axial movement between the first mandrel sleeve and the housing.

26. The integrated bearing section of claim 25, further comprising:

a third mandrel sleeve disposed around the restricted diameter section of the mandrel, wherein the third mandrel sleeve includes a flat profile outer surface;

an outer radial bearing disposed around the third mandrel sleeve and within the housing inner bore, the outer radial bearing including an inner surface having a circumferential groove in axial alignment with the flat profile outer surface of the third mandrel sleeve;

wherein at least one of the spherical members is disposed partially within the circumferential groove of the outer radial bearing and engaging the flat profile outer surface of the third mandrel sleeve for allowing relative axial movement between the outer radial bearing and the third mandrel sleeve.

27. The integrated bearing section of claim 25, wherein the outer thrust bearing is formed of two semi-cylindrical members.

28. A method of absorbing a radial load and a thrust load in a mud lubricated drilling motor, comprising the steps of:

a) providing an integrated bearing section for the drilling motor comprising;

a housing with a housing inner bore;

a mandrel at least partially disposed within the housing inner bore, the mandrel including an outer surface having a series of circumferential grooves;

a plurality of spherical members, wherein each of the spherical members is disposed partially within one of the circumferential grooves of the mandrel;

an outer radial bearing disposed around the mandrel and within the housing inner bore, the outer radial bearing including a flat profile inner surface, wherein at least one of the spherical members engages the flat profile inner surface of the outer radial bearing for allowing relative axial movement between the mandrel and the outer radial bearing; and

an outer thrust bearing disposed around the mandrel and within the housing inner bore, the outer thrust bearing including an inner surface having a circumferential groove, wherein at least one of the spherical members engages the circumferential groove of the outer thrust bearing;

b) transmitting torque to the mandrel to rotate the mandrel relative to the housing, the outer radial bearing, and the outer thrust bearing;

c) absorbing a radial load with the outer radial bearing and absorbing a thrust load with the outer thrust bearing; and

d) allowing relative axial movement between the outer radial bearing and the mandrel as the spherical members or the circumferential grooves wear.

29. The method of claim 28, further comprising the steps of:

e) disassembling the integrated bearing section;

f) increasing a radius of an axial cross section of each of the series of circumferential grooves in the mandrel and increasing a radius of the circumferential groove in the outer thrust bearing; and

g) assembling the integrated bearing section with a plurality of larger spherical members, wherein each of the larger spherical members is disposed partially within one of the circumferential grooves of the mandrel, wherein at least one of the larger spherical members engages the circumferential groove in the outer thrust bearing, wherein a size of the larger spherical members is approximately equal to or slightly less than the radius of the axial cross section of the series of circumferential grooves in the mandrel.

30. A method of absorbing a radial load and a thrust load in a mud lubricated drilling motor, comprising the steps of:

a) providing an integrated bearing section for the drilling motor comprising;

a housing with a housing inner bore, wherein an inner surface of the housing inner bore includes a circumferential groove;

a mandrel at least partially disposed within the housing inner bore, the mandrel including a first mandrel section and a second mandrel section, wherein the first mandrel section includes a flat profile outer surface and the second mandrel section includes an outer surface having a circumferential groove, wherein the circumferential groove in the inner surface of the housing inner bore is axially aligned with the flat profile outer surface of the first mandrel section;

an outer thrust bearing disposed around the second mandrel section and within the housing inner bore, the outer thrust bearing including an inner surface having a circumferential groove in axial alignment with the circumferential groove in the outer surface of the second mandrel section; and

a plurality of spherical members, wherein at least one of the spherical members is disposed partially within the circumferential groove of the second mandrel section and disposed partially within the circumferential groove of the outer thrust bearing, and wherein at least one of the spherical members is disposed partially within the circumferential groove of the housing inner bore and engaging the flat profile outer surface of the first mandrel section for allowing relative axial movement between the mandrel and the housing;

b) transmitting torque to the mandrel to rotate the mandrel relative to the housing and the outer thrust bearing;

c) absorbing a radial load with the housing and absorbing a thrust load with the outer thrust bearing; and

d) allowing relative axial movement between the housing and the mandrel as the spherical members or the circumferential grooves wear.

31. The method of claim 30, further comprising the steps of:

e) disassembling the integrated bearing section;

f) increasing a radius of an axial cross section of the circumferential groove in the second mandrel section, increasing a radius of the circumferential groove in the outer thrust bearing, and increasing a radius of the circumferential groove in the housing; and

g) assembling the integrated bearing section with a plurality of larger spherical members, wherein at least one of the larger spherical members is disposed partially within the circumferential groove of the second mandrel section and disposed partially within the circumferential groove of the outer thrust bearing, and wherein at least one of the larger spherical members is disposed partially within the circumferential groove of the housing inner bore.