Note: Descriptions are shown in the official language in which they were submitted.
CA 02482681 2004-09-28
ENERGIZED SLIP RING ASSEMBLY
FIELD OF INVENTION
The present invention relates to an instrument insert for use in a tool of the
type
comprising an inner member and an outer member, preferably a downhole tool
including a
rotatable inner member or shaft and a non-rotatable outer member or housing.
More particularly,
the present invention relates to a floating instrument insert mounted between
the inner and outer
members of the tool which compensates for slip or relative longitudinal
movement between the
inner and outer members. Preferably, the instrument of the instrument insert
is comprised of a slip
ring assembly. Finally; the present invention further relates to an improved
slip ring assembly.
BACKGROUND OF INVENTION
Directional drilling involves controlling the direction of a borehole as it is
being
drilled. Specifically, the goal of directional drilling is to reach a target
subterranean destination,
typically a potential hydrocarbon producing formation, with a drill string. In
order to conduct the
drilling operation, specialized downhole tools are utilized. These tools often
include various
sensors and other electronic components or equipment for: providing desired
information or data
concerning the environmental conditions of the surrounding formation being
drilled and for
providing desired information or data and communicating instructions
concerning the operational
and directional parameters of the drill string within the borehole.
Various downhole tools typically include an inner member, such as a rotatable
shaft, extending within an outer member, such as a housing. Further, various
instruments may
need to be mounted within the tool in the interface between the inner and
outer members. For
instance, the instrument provided in the interface may be comprised of a
sensor for sensing the
rotation or orientation of the inner member relative to the outer member.
Further, the instrument provided in the interface may be comprised of a
coupling
assembly or device for communicating or transmitting electrical signals or
electricity along the
tool between the inner and outer members. For instance, the electrical signals
or electricity may
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CA 02482681 2004-09-28
embody data, instructions or sensed information being communicated between an
uphole location
and a downhole sensor or electronic component or may provide power being
transmitted from an
uphole power source to a downhole sensor or electronic component.
For example, it is often necessary or desirable to locate or position the
downhole
sensor within a non-rotating member or component of a tpol along a rotary
drill string in order to
permit or facilitate the proper functioning or operation of the sensor.
Accordingly, an electrical
signal embodying data communications, sensed information, instructions and /
or power may need
to be transmitted between a non-rotating member of the tool housing containing
the downhole
sensor and a rotating member of the tool connected with a drive shaft or other
section of the rotary
drill string. Thus, an instrument comprised of a coupling assembly or device
may be mounted
within the interface between the rotating and non-rotating members of the
tool. It is has been
found to be particularly difficult to transmit power across the interface as
compared with data
transmission.
For instance, slip ring assemblies are often utilized for transferring power
and data
between rotating and non-rotating members, as described in United States of
America Patent No.
4,031,544 issued June 21, 1977 to Lapetina; United States of America Patent
No. 5,841,734 issued
November 24, 1998 to Ritter et. al., United States of America Patent No.
6,238,142 issued May
29, 2001 to Harsch and United States of America Patent No. 6,392,561 issued
May 21, 2002 to
Davies et. al.
The slip ring assembly provides for electrical contact between a slip ring and
contact brushes, each being mounted with one of the rotating and non-rotating
members of a tool.
The effectiveness of the transmission of the electrical signals by the slip
ring assembly is
dependent upon the alignment of the contact brushes with the slip ring. Given
the mounting of
these components with the rotating and non-rotating members of the tool, the
effectiveness of the
transmission of the electrical signals is therefore dependent upon the
maintenance of the
longitudinal alignment between the rotating and non-rotating members. In other
words, any
conditions or influences on the members causing relative longitudinal movement
therebetween
may adversely impact the slip ring assembly.
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As an alternative to the use of a slip ring assembly, power transfer and data
communication may be provided by inductive coupling of the rotating and non-
rotating members
of a tool. For instance, an electromagnetic coupling device may be provided in
the interface
between the rotating and non-rotating members of the tool, as described in
United States of
America Patent No. 6,244,361 issued June 12, 2001 to Comeau et, al. However,
inductive
coupling may not be desirable in some applications. Further, inductive
coupling has not been
found to be as effective as a slip ring assembly for the transmission of
power, as compared to data
communications. Finally, any instrument mounted within the interface between
the rotating and
non-rotating members of the tool may be adversely impacted by the relative
longitudinal
movement of those members.
In particular, with respect to downhole tools, conditions may be encountered
in the
borehole by the tool which tend to interfere with the longitudinal alignment
between the inner and
outer members of the tool. In particular, downhole conditions, including
vibration, temperature
changes, pressure changes and the application of tension and compression
forces to the tool, may
result in the longitudinal movement of one member relative to the other. For
instance, the inner
member may undergo an amount of expansion or contraction resulting in
longitudinal movement
relative to the outer member. Where an instrument is mounted within the
interface between the
inner and outer members; this relative longitudinal movement may result in a
misalignment of the
components of the instrument, adversely impacting the proper operation of the
instrument. For
example, where the slip ring assembly is mounted within the interface, the
relative longitudinal
movement of the inner and outer members of the tool may result in a
misalignment of the slip ring
and brush contacts, thus potentially interfering with data or power
transmission therebetween.
Thus, there is a need in the industry for a device or apparatus for mounting
an
instrument in a tool of the type comprising an inner member and an outer
member, wherein the
inner and outer members are capable of an amount of relative longitudinal
movement and wherein
the instrument is required to be mounted in the interface between the members.
More particularly,
there is a need for the device or apparatus to be able to compensate for the
slip or relative
longitudinal movement of the inner and outer members of the tool in order to
permit the proper
functioning or operation of the instrument. Further, there is a need for an
improved slip ring
assembly.
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SUMMARY OF INVENTION
The present invention relates to a device or apparatus for mounting or
positioning
an instrument within a tool, referred to herein as an instrument insert.
Further, the present
invention relates to an instrument insert for use in a tool of the type
comprising an inner member
extending within an outer member, wherein the inner member and the outer
member are capable of
an amount of relative longitudinal movement. The instrument insert permits or
provides for the
mounting of the instrument insert within the tool at a radial position in the
interface between the
inner and outer members. Further, the instrument insert preferably compensates
or adjusts for, or
otherwise counteracts, any slip or relative longitudinal movement or
reciprocation between the
inner and outer members of the tool such that the proper functioning or
operation of the instrument
is not significantly affected or impeded thereby.
Thus, the instrument insert is provided for mounting between reciprocating
inner
and outer members of the tool in that the inner and outer rnernbers move
longitudinally relative to
each other. In addition, the instrument insert may be provided for mounting
between rotating
inner and outer members of the tool. In the preferred embodiment, the
instrument insert is
provided for mounting within the tool between the inner and outer members,
wherein the members
are capable of both an amount of relative longitudinal or reciprocal movement
and relative
rotation. Thus, in the preferred embodiment, the instrument insert does not
interfere with the
relative rotation between the members, while compensating or adjusting for any
relative
longitudinal movement.
Although the instrument insert may be used in any type of tool, apparatus or
structure having inner and outer members capable of relative longitudinal
movement, in the
preferred embodiment of the within invention, the instrument insert is
provided for use in a
downhole tool for a borehole. For instance, the tool may comprise a portion of
a reciprocating or
rotating production or drill string. Preferably, the instrument insert is for
mounting within a
downhole drilling tool between a rotatable member, such as an inner rotatable
shaft, and a non-
rotatable member, such as an outer stationary housing.
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Preferably; the instrument insert is a "floating" insert, in that the
instrument insert is
permitted to move longitudinally within the interface between the inner and
outer members to
counteract or counterbalance any relative longitudinal movement between the
inner and outer
members which could disrupt the operation of the instrument associated with
the instrument insert.
Thus, in the preferred embodiment, the instrument insert is adapted for
mounting within the tool at
a radial position between the inner member and the outer member such that the
instrument insert is
capable of longitudinal movement relative to at least one of the inner member
and the outer
member.
In the preferred embodiment of the invention; the invention is directed at an
instrument insert for a downhole drilling tool including a rotatable inner
member extending within
a substantially stationary outer member. The instrument insert is adapted for
mounting within the
tool at a radial position between the inner and outer members in a manner such
that the instrument
insert is capable of longitudinal movement relative to at least one of the
rotatable inner member
and the stationary outer member. Thus, the instrument insert is capable of
compensating for any
relative longitudinal movement, such as experienced upon the contraction or
expansion of the
inner member downhole within the outer member as a result of downhole
conditions in the
borehole.
In one aspect of the invention, the invention is comprised of an instrument
insert for
a tool of the type comprising an inner member extending within an outer
member, the inner
member and the outer member being capable of an amount of relative
longitudinal movement, the
instrument insert comprising:
(a) a first insert portion adapted to be connected with one of the inner
member and the
outer member, the first insert portion comprising a first instrument component
of an
instrument;
(b) a second insert portion adapted to be connected with the other of the
inner member
and the outer member, the second insert portion comprising a second instrument
component of the instrument; and
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(c) a coupling mechanism for connecting the first insert portion with the
second insert
portion and for maintaining the first insert portion and the second insert
portion in a
fixed relative longitudinal position;
wherein the instrument insert is adapted for mounting within the tool at a
radial position between
the inner member and the outer member such that the instrument insert is
capable of longitudinal
movement relative to at least one of the inner member and he outer member.
Any form or configuration of the instrument insert may be utilized which
permits
the proper functioning of the instrument associated with the instrument insert
and which permits
the instrument insert to move longitudinally relative to at least one of the
inner member and the
outer member. However, preferably, the instrument insert is comprised of the
first insert portion,
the second insert portion and the coupling mechanism as noted above.
Further, the first insert portion and the second insert portion may be coupled
in any
manner and by any mechanism capable of, and suitable for, connecting the
portions to maintain
the first and second portions in a fixed relative longitudinal position. As a
result, the first
instrument component and the second instrument component comprising the first
and second
insert portions respectively are also maintained in a fixed relative
longitudinal position.
In addition, any of the components of the instrument insert may be adapted for
mounting within the tool to permit the desired longitudinal movement relative
to at least one of the
inner member and the outer member. However, in the preferred embodiment, at
least one of the
first insert portion and the second insert portion is adapted to be connected
with one of the inner
and outer members of the tool to provide for the relative longitudinal
movement.
Thus, upon any relative longitudinal movement of the inner and outer members
of
the tool, the first and second insert portions are maintained in a fixed
relative longitudinal position
such that the instrument insert moves longitudinally as a unit or as a
integral member relative to at
least one of the inner and outer members.
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As stated, with respect to the tool, the inner member extends within the outer
member and the inner member and the outer member are capable of an amount of
relative
longitudinal or reciprocal movement. Further, preferably, the inner member and
the outer member
are capable of relative rotation. Thus, the instrument insert is preferably
mounted within the tool
S at a radial position between the inner member and the outer member wherein
the inner and outer
members are capable of relative longitudinal movement and relative rotation.
The instrument
insert may be mounted within any tool providing the inner and outer members.
The first insert portion is preferably adapted to be connected with one of the
inner
member and the outer member, while the second insert portion is adapted to be
connected with the
other of the inner member and the outer member. The first and second insert
portions may be
adapted to be connected to the inner and outer members in any manner and by
any mechanism or
structure capable of, and suitable for; permitting the desired relative
movements between the inner
and outer members, longitudinally and preferably rotatably; while also
permitting the coupling
mechanism to maintain the first and second insert portions in the fixed
relative longitudinal
position.
In the preferred embodiment, wherein the inner member and the outer member are
capable of relative rotation, the first insert portion is adapted to be non-
rotatably connected with
one of the inner member and the outer member and the second insert portion is
adapted to be non-
rotatably connected with the other of the inner member and the outer member.
Further, the
coupling mechanism is comprised of at least one bearing sa that relative
rotation of the inner
member and the outer member results in:relative rotation of the first insert
portion and the second
insert portion.
Although the coupling mechanism is preferably comprised of at least one
bearing,
and more preferably two, the coupling mechanism may be comprised of any device
or structure
which is capable of, and suitable for, connecting and maintaining the first
and second insert
portions in the fixed relative longitudinal position, while also permitting
relative rotation between
the first and second insert portions. Thus, although the first and second
instrument components of
the instrument comprising the first and second insert portions are permitted
to rotate relative to
each other with rotation of the inner and outer members of the tool, the first
and second instrument
CA 02482681 2004-09-28
components are maintained in longitudinal alignment to permit or facilitate
the proper functioning
of the instrument.
Further, the first insert portion may be adapted to be non-rotatably connected
with
either of the inner and outer members, while the second insert portion is
adapted to be non-
rotatably connected with the other of the inner and outer members. However, in
the preferred
embodiment, the first insert portion is adapted to be non-rotatably connected
with the inner
member and the second insert portion is adapted to be non-rotatably connected
with the outer
member. Accordingly, where the inner member rotates within a substantially
stationary outer
member, the first insert portion rotates with the inner member, while the
second insert portion
remains substantially stationary with the outer member.
Further, as indicated, the instrument insert is adapted for mounting in the
tool such
that the instrument insert is capable of longitudinal or reciprocal movement
relative to at least one
of the inner member and the outer member. Although the instrument insert may
be adapted in any
manner to permit this movement, the first and second insert portions are
preferably particularly
adapted to permit the relative longitudinal movement. More particularly, at
least one of the inner
insert portion and the outer insert portion is reciprocably connected with one
of the inner member
and the outer member of the tool such that the instrument insert is capable of
longitudinal
movement relative to that member. In other words, at least one of the inner
insert portion and the
outer insert portion is connected with one of the inner member and the outer
member of the tool in
a manner to permit reciprocal or longitudinal movement relative to that
member.
Further, in the preferred embodiment, where the first insert portion is
connected
with the inner member and the second insert portion is connected with the
outer member, the first
and second insert portions may both be reciprocably connected with the inner
and outer members
respectively. However, preferably, one of the first insert portion and the
second insert portion is
reciprocably connected with its respective inner or outer member, while the
other of the first insert
portion and the second insert portion is non-reciprocably connected with its
respective inner or
outer member. Accordingly, the instrument insert is capable of longitudinal or
reciprocating
movement relative to one of the inner member and the outer member only.
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In the preferred embodiment, the first insert portion is adapted to be non-
reciprocably connected with the inner member so that the first insert portion
moves longitudinally
with the inner member and the second insert portion is adapted to be
reciprocably connected with
the outer member so that the second insert portion moves longitudinally with
the first insert
portion, whereby the instrument insert is capable of longitudinal movement
relative to the outer
member.
Thus, in the preferred embodiment, the first insert portion is adapted to be
non-
rotatably and non-reciprocably connected with the inner member and the second
insert portion is
adapted to be non-rotatably and reciprocably connected with the outer member.
Accordingly,
where the inner member rotates within a substantially stationary outer member,
the first insert
portion rotates and moves longitudinally as a unit with the inner member,
while the second insert
portion remains substantially stationary rotationally with the outer member
but is permitted to
reciprocate longitudinally relarive to the outer member. As a result, the
instrument insert moves
longitudinally as a unit with the inner member relative to the outer member,
while the first and
second instrument components of the instrument are permitted to rotate
relative to each other but
are maintained in a fixed relative longitudinal position.
Preferably, the instrument insert is further comprised of a first connecting
mechanism for non-rotatably and non-reciprocably connecting he first insert
portion with the
inner member. The first connecting mechanism may be comprised of any device,
mechanism,
structure or combinations thereof capable of, and suitable for, both non-
rotatably and non-
reciprocably mounting, connecting, affixing or otherwise attaching the first
insert portion with the
inner member.
However, preferably, the first insert portion is comprised of a mounting
sleeve,
wherein the mounting sleeve is adapted to surround the inner member. Further,
the first
connecting mechanism is associated with the mounting sleeve for non-rotatably
and non-
reciprocably connecting the mounting sleeve with the inner member: In the
preferred
embodiment, the first connecting mechanism is comprised of a locking ring or
taper lock
circumferentially fastened about the mounting sleeve for fixedly connecting
the mounting sleeve
with the inner member.
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Preferably, the instrument insert is also further comprised of a second
connecting
mechanism for non-rotatably and reciprocably connecting the second insert
portion with the outer
member. The second connecting mechanism may be comprised of any device,
mechanism,
structure or combinations thereof capable of, and suitable for, both non-
rotatably and reciprocably
mounting, connecting, affixing or otherwise attaching the second insert
portion with the outer
member.
However, preferably; the second insert portion is comprised of an outer insert
housing, wherein the second connecting mechanism is comprised of one of a key
and a keyway
associated with the outer insert housing which is adapted to engage a
complementary structure
associated with the outer member for non-rotatably and reciprocably connecting
the outer insert
housing with the outer members In the preferred embodiment, a keyway is
associated with the
outer insert housing for engaging a complementary key structure associated
with the outer
member. The keyway of the outer insert housing is configured and oriented to
permit movement
of the key therein longitudinally but not rotationally or circumferentially
relative to the second
insert portion.
The instrument comprising the first and econd instrument components may be any
type of mechanical and / or electronic or electrical mechanism; device or
apparatus desired to be
mounted within the tool. However, the within invention is particularly
applicable where the
instrument is of a type including a first instrument component and a second
instrument component
which are preferably maintained in a fixed relative longitudinal position in
order to facilitate or
ensure the proper functioning of the instrument and which is required or
desired to be mounted
between inner and outer members of a tool capable of longitudinal movement
relative to each
other. Further, the within invention is particularly applicable where the
instrument is required or
desired to be mounted between inner and outer members of a tool capable of
both longitudinal
movement and rotation relative to each other.
In one embodiment, the instrument is comprised of a rotation sensor apparatus
for
sensing the relative rotation of the inner member and the outer member. In
this embodiment, the
first instrument component is comprised of at least one magnet, the second
instrument component
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is comprised of a magnetic sensor for sensing the proximity of the magnet to
the magnetic sensor,
and wherein the first insert portion and the second insert portion are
connected such that the
magnetic sensor is capable of sensing the proximity of the magnet to the
magnetic sensor.
In a further embodiment, the instrument is comprised of a slip ring assembly
for
transmitting electricity between the inner member and the outer member. In
this application, a
reference to "electricity" or an "electrical signal" includes the transmission
or provision of signals
embodying or incorporating either or both data communications and power. In
this further
embodiment, the first instrument component is comprised of a conductive slip
ring; wherein the
second instrument component is comprised of an electrical contact assembly for
providing an
electrical contact with the slip ring, and wherein the first insert portion
and the second insert
portion are connected such that the slip ring engages with the electrical
contact assembly. In other
words, the "electrical contact" permits the transmission or communication of
the electricity or
electrical signal between the components:
Further, the first insert portion and the second insert portion of the
instrument insert
are comprised of a first instrument component and a second instrument
component respectively of
an instrument, such as the rotation sensor apparatus and the slip ring
assembly. Thus, although the
instrument insert is comprised of at least one instrument, it may also be
comprised of a plurality of
instruments. In other words, the first insert portion may be comprised of a
plurality of first
instrument components of a plurality of instruments and the second insert
portion may be
comprised of a plurality of second instrument components of the plurality of
instruments.
Preferably, each of the plurality of instruments is comprised of a first
instrument component and a
compatible second instrument component. Thus, for example, in the preferred
embodiment, the
instrument insert is comprised of two instruments; a first instrument
comprised of the rotation
sensor apparatus and a second instrument comprised of the slip ring assembly.
In addition, in order to facilitate or enhance the proper operation or
functioning of
the instrument or instruments of the instrument insert, any fluid passing
within the instrument
insert is preferably filtered to restrict the passage of any debris or other
deleterious matter into the
instrument insert to the instrument. Therefore, the instrument insert is
preferably comprised of a
filtering mechanism. In the preferred embodiment, the second insert portion is
further comprised
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of an outer insert housing, wherein the outer insert housing is comprised of a
filter mechanism for
filtering a fluid as the fluid passes from an exterior of the outer insert
housing to an interior of the
outer insert housing. However; any suitable type, configuration or structure
of the filtering
mechanism capable of filtering the fluid may be used.
The present invention also relates to innovations in a slip ring assembly. The
innovations may be incorporated into a slip ring assembly which is used with
the instrument insert
of the invention, or the innovations may be incorporated into a slip ring
assembly which is used
independently of the instrument insert of the invention. A slip ring assembly
according to the
invention may incorporate one or more of the innovations.
The innovations are directed at improving the performance of a slip ring
assembly
which is comprised of a slip ring and an electrical contact assembly, wherein
the electrical contact
assembly comprises at least one electrical contact for engaging the slip ring.
A first innovation is directed at improving the engagement between the
electrical
contact and the slip ring, by providing an urging mechanism for urging the
electrical contact
toward engagement with the slip ring.
A second innovation is directed at improving the performance of the slip ring
assembly in response to lateral vibration between the slip ring and the
electrical contact assembly,
by providing a plurality of electrical contacts spaced around a circumference
of the slip ring.
A third innovation is directed at improving the performance of the slip ring
assembly in environments where fluids may tend to pass betyveen the slip ring
and the electrical
contact assembly and thus interfere with the engagement of the electrical
contact with the slip ring,
by providing a wiper between the electrical contact and the slip ring which
inhibits a fluid from
passing between the electrical contact and the slip ring.
In one aspect, a slip ring assembly including all three of the innovations may
comprise:
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(a) a slip ring, wherein the slip ring defines a circumference and wherein the
slip ring
defines an electrical contact groove extending around the circumference of the
slip
ring;
(b) an electrical contact assembly, wherein the electrical contact assembly
comprises a
plurality of electrical contacts spaced around the circumference of the slip
ring for
engaging the electrical contact groove;
(c) an urging mechanism associated with each of the electrical contacts for
urging the
electrical contacts toward engagement with the electrical contact groove; and
(d) a wiper associated with each of the electrical contacts for extending
within the
electrical contact groove to inhibit a fluid from passing through the
electrical
contact groove.
In a second aspect, a slip ring assembly including at least one of the
innovations
may comprise a slip ring and an electrical contact assembly, wherein the
electrical contact
assembly is comprised of an electrical contact for engaging the slip ring and
wherein the electrical
contact assembly is comprised of an urging mechanism for urging the electrical
contact toward
engagement with the slip ring.
In a third aspect, a slip ring assembly including at least one of the
innovations may
comprise a slip ring and an electrical contact assembly, wherein the slip ring
defines a
circumference and wherein the electrical contact assembly is comprised of a
plurality of electrical
contacts spaced around the circumference of the slip ring.
In a fourth aspect, a slip ring assembly including at least one of the
innovations may
comprise a slip ring and an electrical contact assembly, wherein the slip ring
defines a
circumference, wherein the slip ring defines an electrical contact groove
extending around the
circumference of the slip ring, wherein the electrical contact as sembly is
comprised of an electrical
contact for engaging the electrical contact groove, and whereim the electrical
contact assembly is
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further comprised of a wiper for extending within the electrical contact
groove to inhibit a fluid
from passing through the electrical contact groove.
In other aspects, the slip ring assembly may include at least any two of the
innovations.
The urging mechanism may be comprised of any suitable structure, device or
apparatus which is capable of urging the electrical contact to~.vard
engagement with the slip ring
and/or the electrical contact groove. Preferably the urging mechanism is
comprised of a spring
associated with the electrical contact. Where the slip ring assembly is
comprised of more than one
electrical contact, the urging mechanism is preferably comprised of a
plurality of springs so that
one of the springs is associated with each of the electrical contacts.
The electrical contact assembly is preferably, further comprised of a brush
block so
that the electrical contact is carried by the brush block. The urging
mechanism may urge both the
brush block and the electrical contact or only the electrical contact toward
engagement with the
slip ring and/or the electrical contact groove. Where the urging mechanism
urges only the
electrical contact toward engagement with the slip ring and/or the electrical
contact groove, the
urging mechanism is preferably disposed between the brush block and the
electrical contact.
Where the electrical contact assembly is comprised of more than one electrical
contact, the
electrical contact assembly preferably comprises either a single brush block
for all of the electrical
contacts or separate brush blocks for each of the electrical contacts.
The slip ring defines a circumference, which may be an inner circumference but
is
preferably an outer circumference. Where the slip ring assembly includes a
plurality of electrical
contacts extending around the circumference of the lip ring, the electrical
contacts are preferably
spaced substantially evenly unless the expected loading on the slip ring
assembly suggests that the
electrical contacts should be spaced other than evenly. Any number of
electrical contacts rnay be
provided. In a preferred embodiment the electrical contact assembly is
comprised of three
electrical contacts which are spaced substantially 120 degrees apart around
the circumference of
the slip ring.
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The slip ring preferably defines at least one electrical contact groove
extending
around the circumference of the slip ring so that; the electrical contact
travels in the electrical
contact groove. Where more than one electrical "channel" is required either
for redundancy or for
transmission of different electrical signals, the slip ring may define a
plurality of electrical contact
grooves and the electrical contact may comprise a plurality of electrical
contact leads for engaging
with the electrical contact grooves.
The slip ring assembly may include a wiper whenever it is expected that fluid
passing between the slip ring and the electrical contact may interfere with
the engagement between
the slip ring and the electrical contact. The wiper is preferably comprised of
a member which
partially or fully blocks the passageway which is provided between the slip
ring and the electrical
contact assembly. The wiper is particularly advantageous where the slip ring
defines one or more
electrical contact grooves, since these grooves provide a relatively large
passageway between the
slip ring and the electrical contact assembly.
The wiper may be comprised of any structure, apparatus or device which is
capable
of partially or fully blocking the passageway between the slip ring and the
electrical contact
assembly. Preferably the wiper provides some clearance between the slip ring
and the electrical
contact assembly in order to minimize wear and in order to avoid interference
by the wiper with
the engagement between the electrical contact and the slip ring.
Preferably the wiper is comprised of one or more wiper members. A wiper member
may be any shape and size which is compatible with the slip ring and the
electrical contact
assembly. Where the electrical contact is carried by a brush block, the wiper
is preferably located
on the brush block.
The slip ring and the electrical contact assembly are typically adapted to
rotate
relative to each other so that the electrical contact is comprised of an
upstream side and a
downstream side. The upstream side of the electrical contact ns the leading
edge of the electrical
contact and the downstream side of the electrical contact is the trailing edge
of the electrical
contact during relative rotation between the slip ring and the electrical
contact assembly.
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CA 02482681 2004-09-28
The wiper is preferably positioned adjacent to the upstream side of the
electrical
contact. The wiper may also be positioned adjacent to the downstream side of
the electrical
contact so that the wiper is positioned on both sides of the electrical
contact.
The wiper rnay be comprised of an elongated rib which is positioned adjacent
to the
upstream side of the electrical contact, which extends within the electrical
contact groove, and
which is substantially parallel to he electrical contact groove.
Alternatively, the wiper may be comprised of an upstream wiper member
positioned
adjacent to the upstream side of the electrical contact and a downstream wiper
member positioned
adjacent to the downstream side of the electrical contact. Preferably the
upstream wiper member
is comprised of an upstream elongated rib which extends substantially parallel
to the electrical
contact groove and the downstream wiper member is comprised of a downstream
elongated rib
which extends substantially parallel to the electrical contact groove.
Where the electrical contact assembly is comprised of a plurality of
electrical
contacts, a wiper is preferably associated with each of the electrical
contacts. Where the slip ring
defines a plurality of electrical contact grooves and the electrical contact
is comprised of a
plurality of electrical contact leads, the wiper is preferably comprised of
wiper members for
extending within each of the electrical contact grooves.
SUMMARY OF DRAWINGS
Embodiments of the invention will now be described with reference to the
accompanying drawings, in which:
Figure 1 is a longitudinal sectional view of a preferred embodiment of an
instrument
insert mounted within an inner member and an outer member of a tool;
Figure 2 is a more detailed portion of the longitudinal sectional view of the
instrument insert within the tool as shown in Figure 1;
-16-
CA 02482681 2004-09-28
Figure 3 is an end view of the instrument insert and a portion of the outer
member
of the tool shown in Figure 1;
Figure 4 is a longitudinal sectional view of the instrument insert and the
portion of
the outer member of the tool taken along line 4 - 4 of Figure 3;
Figure S is a longitudinal sectional view of the instrument insert and the
portion of
the outer member of the tool taken along line 5 - 5 of Figure 3;
Figure 6 is a longitudinal sectional view of the instrument insert and the
portion of
the outer member of the tool taken along line 6 - 6 of Figure 3;
Figure 7 is a longitudinal ectional view of the instrument insert in isolation
taken
along line 7 - 7 of Figure 3;
Figure 7;
Figure 8 is a perspective view of the instrument insert in isolation as shown
in
Figure 9 is a perspective view of a slip ring assembly of the present
invention
comprising a slip ring and an electrical contact assembly, wherein the
electrical contact assembly
is comprised of three electrical contacts;
Figure 10 is a side view of the slip ring assembly shown in Figure 9;
Figure 11 is a top view of the slip ring assembly shown in Figure 9;
isolation;
Figure 12 is a perspective view of a single electrical contact of Figure 9,
shown in
Figure 13 is an end view of an upstream side of the electrical contact shown
in
Figure 12;
_1~_
CA 02482681 2004-09-28
Figure 14 is a side view of the electrical contact shown in Figure 12; and
Figure 15 is a sectional view of the electrical contact taken along lines 15 -
15 of
Figure 13.
DETAILED DESCRIPTION
Referring to Figures 1 and 2, the invention is directed at an instrument
insert (20)
for a tool {22), wherein the instrument insert (20) is associated with or
comprised of an instrument
(21) as described herein. The instrument insert (20) is particularly for use
in a tool {22) of the type
comprising an inner member (24) extending within an outer member (26), wherein
the inner
member (24) and the outer member (26) are capable of an amount of relative
longitudinal
movement. Longitudinal movement or reciprocal or reciprocating movement is
movement in the
direction of the longitudinal axes of the inner and outer members (24, 26).
Further, although not
required, in the preferred embodiment, the inner member (24) and the outer
member (26) are also
capable of relative rotation.
The instrument insert (20) may be used in any tool (22) of the type described.
However, the instrument insert (20) is preferably used in a downhole tool for
insertion in a
borehole. More particularly, the downhole tool is preferably a downhole
drilling tool.
Specifically, the tool is preferably incorporated into or comprises a portion
or section of a drill
string which extends from the surface within the borehole.
Preferably, the tool (22) is incorporated in or comprises a portion or section
or the
whole of a drilling direction control device for orienting a drilling system
downhole, such as a
rotary drilling system. In the preferred embodiment, the tool (22) is
comprised of the drilling
direction control device described in United States of America Patent No.
6,244,361 issued June
12, 2001 to Comeau et. al. The drilling direction control device, and thus the
tool (22), is
comprised of a rotatable shaft (28) which is connectable with the drill string
and a housing {30) for
rotatably supporting a length of the shaft {28) for rotation therein. A
portion of the tool (22)
having the instrument insert (20) mounted therein is shown in Figures 1 and 2.
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CA 02482681 2004-09-28
Thus, in the preferred embodiment, the inner member (24) is comprised of the
rotatable shaft (28) while the outer member (26) is comprised of the housing
{30). To permit or
facilitate the relative rotation between the inner and outer members (24, 26),
being comprised of
the rotatable shaft (28) and the housing (30) respectively, the outer member
(26) may be
associated with a device (not shown) far restraining the rotation of the outer
member (26) upon
rotation of the inner member (24), such as during the drilling operation.
Preferably, the outer
member (26) is maintained or restrained rotationally in a substantially
stationary position.
Referring to Figures 1 and 2, the inner member (24) extends within the outer
member (26). The inner member (24) of the tool {22) may be comprised of a
single element or
component or may be comprised of a plurality of elements, sections or
components connected,
fastened or otherwise fixedly joined together to form the inkier member (24).
In the preferred
embodiment, the inner member (24) is comprised of an elongate member, such as
the rotatable
shaft (28), having an outer circumferential or perimetrical surface (32) and
defining a longitudinal
axis (34) extending therethrough.
Similarly, the outer member (26) of the tool (22) may be comprised of a single
element or component or may be comprised of a plurality ojP elements, sections
or components
connected, fastened or otherwise fixedly joined together to form the outer
member (26). In the
preferred embodiment, the outer member (26) is comprised of a plurality of
elements or sections
which are fixedly or rigidly connected or affixed together to move as a unit.
In particular, the
outer member (26) is comprised of an elongate and substantially tubular or
cylindrical housing
member (35), such as the housing (30), having a bore (36) defining an inner
circumferential or
perimetrical surface (38) therein.
In addition, the outer member (26) is further comprised of at least one
housing
insert (40) contained within the bore {36) of the housing member (35) and
fixedly and non-
rotatably connected with the housing member (35): The housing insert (40) is
comprised of an
elongate and substantially tubular or cylindrical member having an outer
circumferential or
perimetrical surface (42) which is affixed, mounted or fastened with the inner
surface (38) of the
housing member (35). Further, the housing insert (40) has a bore (44) defining
an inner
circumferential or perimetrical surface (46) therein: The housing member {35)
and the housing
-19-
CA 02482681 2004-09-28
insert (40) together define a longitudinal axis (48) of the outer member (26)
extending
therethrough.
Preferably, the longitudinal axis (34) of the inner member (24) is coincident
or
concurrent with the longitudinal axis (48) of the outer member (26). A
reference to longitudinal
movement herein refers to movement along or in the direction of the
longitudinal axes (34, 48).
Further, the inner member (24) extends within and is supported by the outer
member (26) such that
an amount of relative longitudinal movement is permitted therebetween.
Further, in the preferred
embodiment, the inner member (24) is supported by the outer member (26) such
that the inner
member (24) and the outer member (26) are capable of relative rotational
movement about their
longitudinal axes (34, 48). Any mechanism; apparatus, devicE; or structure
capable of rotationally
supporting the inner member (24) within the outer member (~6) in the described
manner may be
used. For instance, one or more radial bearings (50) may be provided between
the inner and outer
members (24, 26) for rotationally supporting and centralizing the inner member
(24) within the
outer member (26).
Finally, the inner member (24) is supported within the outer member (26) such
that
a radial space or gap (52) is provided between the inner and outer members
(24, 26) for
positioning of the instrument insert (20) therein. Preferably, the radial
space (52) is provided
between the outer surface (32) of the inner member (24) and the inner surface
(40) of the housing
insert (40) comprising the outer member (26). As indicated, the instrument
insert (20) is mounted
within the tool (22) at a radial position, preferably within the radial space
(52), between the inner
and outer members (24, 26).
Referring to Figures l- 8, the instrument insert (20) is comprised of a first
insert
portion (54), a second insert portion (56) and a coupling mechanism (58). The
first insert portion
(54) is adapted o be connected with one of the inner member (24) and the outer
member (26) of
the tool (22), while the second insert portion (56) is adapted to be connected
with the other of the
inner member (24) and the outer member (26).
In the preferred embodiment, the first insert portion (54) is adapted to be
connected
with the inner member (24). The first insert portion (54) may have any shape
or configuration
-20-
CA 02482681 2004-09-28
compatible for connecting with the inner member (24) in the desired manner as
described herein.
However, preferably, the first insert portion (54) is substantially tubular or
cylindrical defining a
circumferential inner surface (60); an outer surface (62) and opposed first
and second ends (64,
66). The inner surface (60) of the first insert portion (54) is preferably
sized for receipt of the
inner member (24) of the tool (22) therein. Further, the inner Surface (60) of
the first insert portion
(54) is preferably particularly adapted to be connected with the adjacent
outer circumferential
surface (32) of the inner member (24).
Further, in the preferred embodiment, the second insert portion (56) is
adapted to be
connected with the outer member (26). The second insert portion (56) may have
any shape or
configuration compatible for connecting with the outer member (26) in the
desired manner as
described herein. However, preferably, the second insert portion (56) is also
substantially tubular
or cylindrical defining an inner surface (68), a circumferential outer surface
(70) and opposed first
and second ends (72, 74). The second insert portion (56) is sized or
configured for receipt of at
least a part of the first insert portion (54) therein Further, the second
insert portion (56) is
preferably sized or configured for receipt within the outer member (26),
particularly the housing
insert (40). Thus, the outer surface (70) of the second insert portion (56) is
preferably particularly
adapted to be connected with the adjacent inner surface (46) of the housing
insert (40) comprising
the outer member (26).
As stated, the instrument insert (20) is adapted for mounting within the
radial space
(52) such that the instrument insert (20) is capable of longitudinal movement
relative to at least
one of the inner member (24) and the outer member (26). Thus, one of the first
insert portion (54)
and the second insert portion (56) is capable of longitudinal movement
relative to at least one of
the inner member (24) and the outer member (26).
In the preferred embodiment, the instrument insert (20) is adapted for
mounting
such that the instrument insert (20) is capable of longitudinal movement
relative to the outer
member (26) alone. Thus, the first insert portion (54) is adapted to be non-
reciprocably connected
with the inner member (24) so that the first insert portion (54) moves
longitudinally, or
reciprocates along the longitudinal axis (34), with the inner member (24).
Further, the second
insert portion (56) is adapted to be reciprocably connected with the outer
member (26) so that the
-21-
CA 02482681 2004-09-28
second insert portion (56) moves longitudinally or reciprocates with the first
insert portion (54) as
a result of the coupling mechanism (58) which maintains fhe first insert
portion (54) and the
second insert portion (56) in a fixed relative longitudinal position. In other
words, the second
insert portion (56) moves longitudinally, or reciprocates along the
longitudinal axis (48), relative
to the outer member (26).
More particularly, in the preferred embodiment, the inner surface (60) of the
first
insert portion (54) is adapted to be non-reciprocably connected with the
adjacent outer surface (32)
of the inner member (24), while the outer surface (70) of the second insert
portion (56) is adapted
to be reciprocably connected with the adjacent inner surface (46) of the
housing insert (40). In
other words, the first insert portion (54) is connected with the inner member
(24) in a manner
inhibiting or preventing any relative longitudinal or reciprocal movement
therebetween, while the
second insert portion (56) is connected with the housing insert (40) in a
manner permitting an
amount of relative longitudinal or reciprocal movement therebetween.
In addition, in the preferred embodiment, the inner and outer members (24, 26)
of
the tool {22) are capable of relative rotation. Further, each of the first
insert portion (54) and the
second insert portion (56) is further' adapted to be non-rotatably connected
with one of the inner
member (24) and the outer member (26). Thus, in the preferred embodin3ent, the
inner surface
(60) of the first insert portion (54) is adapted to be non-reciprocably and
non-rotatably connected
with the adjacent outer surface (32).of the inner member (24), while the outer
surface (70) of the
second insert portion (56) is adapted to be reciprocably and non-rotatably
connected with the
adjacent inner surface (46) of the housing insert (40).
The first insert portion (54) maybe adapted to non-rotatably and non-
reciprocably
connect with the inner member (24) in any manner and by any mechanism, device
or structure
capable of restraining or preventing any relative rotation; or longitudinal
movement between the
first insert portion (54) and the inner member (24). Referring to Figures 1, 2
and 4 - 6, in the
preferred embodiment, the instrument insert (20) is further comprised of a
first connecting
mechanism {76) for non-rotatably and non-reciprocably connecting the first
insert portion (54) and
the inner member (24). More particularly, the first connecting mechanism (76)
fixedly or rigidly
connects, attaches, fastens or otherwise mounts, either permanently or
removably and either
-22-
CA 02482681 2004-09-28
directly or indirectly, the inner surface (60) of the first insert portion
(S4) with the outer surface
(32) of the inner member (24).
The first insert portion (54) may be comprised of a single member, component
or
S element providing an integral unit. However, preferably, the first insert
portion (S4) is comprised
of a plurality of members, components or elements connected, fastened or
otherwise retained
together to define the first insert portion (54). For instance, in the
preferred embodiment, the first
insert portion (54) is comprised of an inner mounting sleeve (78) and an outer
sleeve (79). The
inner mounting sleeve (78) comprises or defines the inner surface (60) of the
first insert portion
(S4) and extends between the first and second ends (64, 66). The mounting
sleeve (78) has a
tubular configuration or structure and is adapted to surround the inner member
(24) such that the
inner member (24) is receivable therein. The outer sleeve (79) comprises or
defines at least a
portion of the outer surface (62) of the first insert portion (S4) and also
has a tubular configuration
or structure such that it is adapted to surround a portion of the mounting
sleeve (78) between the
first and second ends (64, 66).
Refernng particularly to Figure 7, in the preferred embodiment, the outer
sleeve
(79) is provided for carrying or retaining various components or elements of
the first insert portion
(S4) as discussed below. The outer: sleeve (79) may be retained in a desired
position or location
relative to the mounting sleeve (78) by an retaining structure or device.
However, preferably, the
outer sleeve (79) is retained in position about the mounting sleeve (78)
between a shoulder (80)
defined by the mounting sleeve (78) and a retaining ring (82) extending about
the mounting sleeve
(78). One or more spacers (84) may also be used as desired or required to
obtain or retain the
desired positioning of the outer sleeve (79) on the mounting sleeve (78). In
other words; the outer
2S sleeve (79) is retained in abutment between the shoulder (80) of the
mounting sleeve (78) and the
retaining ring (82) with one or more spacers (84) as required.
Further, the first insert portion (S4) and the second insert portion (S6) are
maintained in a fixed relative longitudinal position by the coupling mechanism
(S8). Although the
first insert portion (S4) and the second insert portion (S6) may be maintained
in any fixed positions
relative to each other, the second insert portion (S6) is preferably fixed
about all or a part of the
first insert portion (S4) such that at least a part of the outer surface (62)
of the first insert portion
-23-
CA 02482681 2004-09-28
(54) is opposed or adjacent to at least a part of the inner surface (68) of
the second insert portion
(56). In the preferred embodiment, the second insert portion (56) is fixed in
a position about the
first insert portion (54) such that the first and second ends (64, 66) of the
first insert portion (54)
extend from the first and second ends (72, 74) of the second insert portion
(56) respectively.
Specifically, the mounting sleeve (78), defining the first and second ends
(64, 66) of the first insert
portion (54), extends from the first and second ends (72, 74) of the second
insert portion (56).
The first connecting mechanism (76) is preferably associated with the mounting
sleeve (78) for non-rotatably and non-reciprocably connecting the mounting
sleeve (78) with the
inner member (24). The first connecting mechanism (76) may be associated with
the mounting
sleeve (78) at any position or location along its length between the first and
second ends (64, 66)
of the f rst insert portion (54). However, preferably, the first connecting
mechanism (76) is
associated with the mounting sleeve (78) at one of the first and second ends
(64, 66) of the first
insert portion (54). In the preferred embodiment, the first connecting
mechanism (76) is
associated with the mounting sleeve (78) at the first end (64) where the
mounting sleeve (78)
extends from the first end (72) of the second insert portion (56).
In addition, as noted above, at least one radial bearing (50) may be provided
between the inner and outer members ' (24, 26) for rotationally supporting and
centralizing the
inner member (24) within the outer tnernber (26), as shown in Figures 2 and 4 -
6. In the preferred
embodiment, the second end (66) of the first insert portion (54) comprised of
the mounting sleeve
(78) extends from the second end (74) of the second insert portion (56) to a
position adjacent the
housing insert (40) comprising the outer member (26). In other words, the
mounting sleeve (78),
at the second end (66) of the first insert portion (54), is positioned or
located between the outer
surface (32) of the inner member (24) and the inner surface (46) of the
housing insert (40). Given
that the mounting sleeve (78) is fixed with the inner member (24), the
mounting sleeve (78) rotates
relative to the housing insert (40).
As a result, in the preferred embodiment, at least one radial bearing (50) is
positioned between the mounting sleeve (78), at the second end (66) of the
first inert portion (54),
and the adjacent inner surface (46); of the housing insert (40). The radial
bearing (50) may be
maintained in the desired position between the mounting sleeve (78) and the
housing insert (40) by
-24-
CA 02482681 2004-09-28
any mechanism or structure. However, in the preferred embodiment, the radial
bearing (50) is
maintained in abutment with a shoulder (86) defined by the inner surface (46)
of the housing insert
(40). Specifically, the radial bearing (50) is held or maintained between the
shoulder (86) and a
retaining ring (88) mounted with, and extending from, the inner surface (46)
of the housing insert
(40). Finally, in order to maintain the bearing (50) in the desired position
upon longitudinal
movement of the inner member (24), the bearing (50) is urged away from the
retaining ring (88)
and into abutment with the shoulder (86) by a biasing mechanism or device,
such as a spring (90).
In the preferred embodiment, the spring (90) is comprised of at least one wave
spring.
Preferably, the first connecting mechanism (76) is comprised of any mechanism,
device or structure capable of fixedly or rigidly connecting, attaching or
otherwise fastening the
mounting sleeve (78) about the inner member (24). Referring to Figures l, 2
and 4 - 6, in the
preferred embodiment, the first connecting mechanism (76) is comprised of a
taper lock (92), also
referred to as a locking ring. In the preferred embodiment, the taper lock
(92) is comprised of a
three piece taper lock for tightening or cinching the mounting sleeve (78)
about the inner member
(24).
The taper lock (92) is comprised of a circumferential inner ring (94) which is
mounted about the mounting sleeve (78) at, adjacent or in proximity to the
first end (64) of the
first insert portion (54). Although the inner ring (94) may be mounted in any
manner, preferably,
the inner ring (94) is mounted by a plurality of screws or bolts (96)
extending between the inner
ring (94) and the mounting sleeve (78) and spaced about the circumference of
the inner ring (94).
Further, the inner ring (94) has an upper surface (98) defining two sloping or
tapered portions
(100) which each slope or taper outwardly away from a center of the upper
surface (98) in an
inward direction towards the mounting sleeve (78), as shown in the Figures.
The taper lock (92) is further comprised of two opposed circumferential outer
rings
( 102) which surround the inner ring (94). Each outer ring ( 102) has a lower
surface (104) which
defines a compatible slope or taper for engagement with one of the tapered
portions (100) of the
upper surface (98) of the inner ring (94). When the outer rings (102) are
mounted in position
about the inner ring (94), the screws (96) mounting the inner ring (94) with
the mounting sleeve
(78) are positioned between the outer rings (102). Further; the-tapered
portions (100) of the upper
-25-
CA 02482681 2004-09-28
surface (98) of the inner ring (94) engage the tapered lower surfaces (104) of
the outer rings (102).
Finally, a plurality of bolts or screws (106) extend between the opposed outer
rings {102).
Tightening of the bolts (106) draws the outer rings (102) into closer
proximity to each other,
which moves the lower surface (104) of each outer ring (102) along the tapered
portions (100) of
the inner ring (94) to cause the mounting sleeve (78) to more closely or
firmly engage the inner
member (24).
The second insert portion (56) may be adapted to non-rotatably and
reciprocably
connect with the outer member (26) in any manner and by any mechanism, device
or structure
capable of restraining or preventing any relative rotation, while permitting
an amount of
longitudinal movement, between the second insert portion: (56) and the outer
member (26). In the
preferred embodiment, the instrument insert (20) is further comprised of a
second connecting
mechanism (108) for non-rotatably and reciprocably connecting the second
insert portion (56) and
the outer member (26). More particularly, the second connecting mechanism (
108) connects,
attaches, fastens or otherwise mounts in the desired manner, either
permanently or removably and
either directly or indirectly, the outer surface {70) of the second insert
portion (56) with the inner
surface (46) of the outer member (26), particularly the housing insert (40).
The second insert portion (56) may be comprised of a single member, component
or
element providing an integral unit ar a plurality of members, components or
elements connected,
fastened or otherwise retained together o define the second insert portion
(56). In the preferred
embodiment, the second insert portion (56) is comprised of an outer insert
housing (110).
Preferably, the outer insert housing '(110) comprises or defines both the
inner and outer surfaces
(68, 70) of the second insert portion (56) and extends between the first and
second ends (72, 74).
The outer insert housing (110) preferably has a tubular confguration or
structure and is adapted to
surround the first insert portion (54) between the first and second ends (64,
66) thereof, as
discussed above, such that the first insert portion (54) extends through the
outer insert housing
( 110).
In the preferred embodiment, the outer insert housing (110) may be retained in
a
desired position or location relative to the first insert portion (54) by any
retaining structure or
-26-
CA 02482681 2004-09-28
device. However, preferably, the outer insert housing (110) is retained in
position about the first
insert portion (54) by the coupling mechanism (58) as described in detail
below.
Referring to Figures l, 2 and 4, the second connecting mechanism (108) is
preferably associated with the interface between outer insert housing ( 110),
defining the outer
surface (70) of the second insert portion (56), and the housing insert (40),
defining the inner
surface (46) of the outer member (26). Specifically, the second connecting
mechanism (108) is
comprised of complementary or compatible structures on each of the adjacent
surfaces of the outer
insert housing (110) and the housing insert (40) for non-rotatably and
reciprocably connecting the
outer insert housing ( 108) with the housing insert (40). Any complementary or
compatible
structures capable of providing the 'desired non-rotatable, reciprocable
connection may be used,
such as complementary longitudinally oriented splines and grooves or
complementary key and
keyway structures.
The second connecting mechanism ( 108) may be associated with the outer insert
housing (110) at any position or location along its length between the first
and second ends (72,
74) of the second insert portion (56). However, preferably, the second
connecting mechanism
(108) is associated with the outer insert housing (110) at about a mid-point
between, or
approximately centrally of, the first and econd ends (72, 74).
Referring to Figures l, 2 and 4, preferably, the second connecting mechanism
(108)
is comprised of one of a key and a keyway associated with the outer insert
housing (110) which is
adapted to engage a complementary structure associated with the outer member
(26), particularly
the housing insert (40), for non-rotatably and reciprocably connecting the
outer insert housing
( 110) with the outer member (26). In the preferred embodiment, at least one
elongate,
longitudinally oriented keyway ( 112), being a groove or slot, is defined by
the outer surface (70)
of the outer insert housing (110) of the second insert portion (56). Each
keyway (112) is provided
for receiving at least one complementary key (114) structure therein. Each key
(114) is fixedly
mounted or fastened with, and extends from, the inner surface (46) of the
housing insert (40). In
the preferred embodiment, two keys '(114) extend from the housing insert (40)
for receipt within a
single keyway (112) defined by the outer insert housing (110). However, any
number of keyways
(112) and complementary keys (114) may be used as desired or required for a
particular
-27-
CA 02482681 2004-09-28
application. Further, in the preferred embodiment, each key (114) is
particularly comprised of a
capscrew having an end extending from the housing insert (40) to act as or
provide the key
structure ( 114).
S In addition, a device or structure may be further provided in the interface
between
the outer insert housing (110) and the housing insert (40} for facilitating
the longitudinal
movement between the instrument insert {20) and the outer member (26) and for
assisting with the
centralization of the instrument insert (20) within the outer member (26). In
the preferred
embodiment, at least one circumferential glide button or glide ring (116) is
mounted with at least
one groove (118) defined by the outer surface (70) of the outer insert housing
(110) for engaging
the adjacent surface of the housing insert (40).
When the first insert portion (S4) and the second insert portion {S6) are
coupled to
form the instrument insert {20) and the instrument insert (20) is positioned
within the radial space
1S {S2) provided between the inner and outer members (24, 26) of the tool
{22), the other components
of the tool (22) must be positioned within the tool (22) adjacent to the
instrument insert (20) in a
manner permitting any necessary or required longitudinal movement of the
instrument insert (20)
consequent upon the relative longitudinal movement of he inner and outer
members (24, 26).
Thus, the radial space (S2) provided for the instrument insert (20) has a
length sufficient to
accommodate the instrument insert {20) and to accommodate any necessary or
required
longitudinal movement of the instrument insert (20).
More particularly; referring to Figures 2 and 4 - 6, an axial or longitudinal
gap ( 120)
is provided in the radial space (S2) between the instrument insert (20) and
the other components of
2S the tool (22) located or positioned longitudinally at either end of the
instrument insert (20). The
total amount or length of the longitudinal gap (120) determines the amount of
longitudinal
movement or travel permitted by the instrument insert (20) relative to the
outer member (26). The
total amount or length of the longitudinal gap ( 120) is equal to the combined
amounts or lengths of
the longitudinal gaps at either end, of the instrument insert (20). For
instance, in the preferred
embodiment, when assembling the instrument insert (20) within the tool (22),
the instrument insert
(20) is preferably centralized within the radial space (S2) to approximately
equalize the amount or
portions of the longitudinal gap ( 120} present on either side of the
instrument insert {20). Thus, a
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CA 02482681 2004-09-28
portion of the total gap (120) is present on either side of the instrument
insert (20) to permit the
desired longitudinal movement of the instrument insert (20) relative to the
outer member (26) in
either direction. In other words, the amount or length of the total
longitudinal gap (120) is
selected depending upon the desired amount of travel of the instrument insert
(20) longitudinally
relative to the outer member (26).
In particular, the axial or longitudinal gap (120) is comprised of a first
portion (122)
and a second portion ( 124). The combination of the first portion ( 122) and
the second portion
(124) provides the total longitudinal gap (120) or amount of available travel
of the instrument
insert (20) within the radial space {52): Referring to Figure 2, in the
preferred embodiment, the
first portion (122) of the longitudinal gap (120) is located or positioned
between the first end (72)
of the second insert portion {56) and the adjacent component of the tool (22),
being a spacer kit
(126), including one or more spacers, shims and / or springs, for an adjacent
sub or tubular
member (128). The second portion (124) of the longitudinal gap {120) is
located or positioned
between the second end (74) of the second insert portion (56) and the adjacent
component of the
tool (22), being an end of the housing insert (40) comprising the outer member
(26).
Further, in order to filter any fluid passing within the instrument insert
(20) from
outside the instrument insert (20), the instrument insert (20) is preferably
further comprised of a
filter mechanism (130), as particularly shown in Figures 4 and 5. The filter
mechanism (130)
preferably inhibits or prevents the passage of any debris or deleterious
material, such as metal
particles or filings from the tool (22), into the instrument insert (20) which
may interfere with its
proper functioning or the functioning of the instrument {21) associated
therewith, as described
further below.
The filter mechanism {130) may be comprised of any device or mechanism capable
of filtering the fluid from the surrounding tool (22) for passage within the
instrument insert (20).
Further, the filter mechanism (130) may be associated with any part or element
comprising the
instrument insert (20). Preferably; the outer insert housing (110) is
comprised of the filter
mechanism (130) for filtering a fluid as the fluid passes from an exterior of
the outer insert
housing ( 110), being outside the instrument insert (20), to an interior of
the outer insert housing
(110), being within the instrument insert (20). In the preferred embodiment,
the filter mechanism
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CA 02482681 2004-09-28
(130) is comprised of a fluid channel (132) defined by the outer insert
housing (110) and
extending from the interior of he outer insert housing (110) to the second end
(74) of the second
insert portion (56) to communicate with the exterior of the outer insert
housing (110). In addition,
the filter mechanism (130) is comprised of a filter material or screen (134)
disposed within the
fluid channel (122) adjacent the second end (74) of the second insert portion
(56).
As previously indicated, the instrument insert (20) is further comprised of or
associated with an instrument (21 ). Specifically, the structure of the
instrument insert (20) permits
the components of the instrument (21) associated therewith to be maintained in
a fixed relative
longitudinal position while the inner and outer members (24; 26) of the tool
(22) are permitted to
rotate and reciprocate relative to each other: Thus, the instrument insert
(20) facilitates the proper
operation and functioning of the instrument (21) associated with or comprising
the instrument
insert (20).
Referring to Figures 3 - 8, preferably, the first insert portion (54) is
comprised of a
first instrument component (136) of he instrument (21). Further, the second
insert portion (56) is
comprised of the second instrument component ( i 38) of the instrument (21 ).
In other words, the
instrument (21) is comprised of the first instrument component (136) and the
second instrument
component (138). The coupling mechanism (58) connects the first insert portion
(54) with the
second insert portion (56) and maintains the first and second insert portions
(54, 56) in a fixed
relative longitudinal position. Accordingly, the first instrument component (
136) a.nd the second
instrument component (138) are also maintained in a fixed relative
longitudinal position.
The first insert portion (54) comprised of the first instrument component
(136) and
the second insert portion (56) comprised of the second instrurr~ent component
(138) are maintained
in a fixed relative longitudinal position by the coupling mechanism (58).
Although the first insert
portion (54) and the second insert portion (56) may be maintained in any fixed
positions relative to
each other, the second insert portion (56) is preferably fixed about all or a
part of the first insert
portion (54) such that at least a part of the outer surface (62) of the first
insert portion (54) is
opposed or adjacent to at least a part of the inner surface (68) of the second
insert portion (56).
Further, the second insert portion (56) is preferably fixed about the first
insert portion (54) in a
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CA 02482681 2004-09-28
position such that the second instrument component (138) is opposed to the
first instrument
component (136).
In the preferred embodiment, the second insert portion (56) is fixed in a
position
about the first insert portion {54) sucf that the first and second ends (64,
66) of the first insert
portion extend from the first and second ends (72, '74) of the second insert
portion (56)
respectively. Specifically, the mounting sleeve (78), defining the first and
second ends (64, 66) of
the first insert portion (54), extends from the first and second ends (72, 74)
of the second insert
portion {56). Further, the second insert portion (56) is fixed in a position
about the first insert
portion (54) such that the second instrument portion (138) and the first
instrument portion (138)
are opposed to each other to permit the fiznctioning of the instrument (21)
comprised of the
components (136, 138).
The coupling mechanism,(58) maybe comprised of any device, apparatus, members
or elements capable of, and suitable for; connecting the first and second
insert portions (56, 58)
and maintaining them in a fixed relative longitudinal position. Preferably,
the coupling
mechanism (58) performs this function, while also permitting the relative
rotation of the first and
second insert portions (54, 56) consequent to the relative rotation of the
inner and outer members
(24, 26) of the tool (22). Thus, the coupling mechanism {58) is preferably
comprised of at least
one bearing so that relative rotation of the inner member (24) and the outer
member (26) results in
relative rotation of the first insert portion (54) and the second insert
portion (56), and thus relative
rotation of the first instrument component (136) and the second instrument
component (138).
In the preferred embodiment, the coupling mechanism (58) is comprised of a
first
coupling bearing ( 140) and a second coupling bearing ( 142). Each of the
coupling bearings ( 140,
142) is preferably at least a radial bearing. However, in the preferred
embodiment, each of the
coupling bearings ( 140, 142) is a radial and a thrust bearing. More
particularly, each of the
coupling bearings (140, 142) is comprised of a four-point contact ball
bearing. The coupling
bearings (140, 142) may be positioned at any location between the first and
second insert portions
(54, 56) which does not interfere with the first and second instrument
components (136, 138).
However, preferably, the coupling bearings ( 140, 142) are positioned a spaced
distance apart to
enhance the stability of the instrument insert (20). In the preferred
embodiment; the first coupling
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CA 02482681 2004-09-28
bearing (I40) is positioned at, adjacent or in proximity to the first end (72)
of the second insert
portion (56), while the second coupling bearing (I42) is positioned at,
adjacent or in proximity to
the second end (74) of the second insert portion (56). in addition, any
mechanism, device or
structure may be used to maintain each of the first and second coupling
bearings (140, I42) in the
desired positions between the first and second insert portions (54, 56).
In the preferred embodiment, the first coupling bearing (140) is positioned
adjacent
the first end (72) of the second insert portion (56) between the inner surface
(68) of the second
insert portion (56) comprised of the outer insert housing ( 110) and the outer
surface (62) of the
first insert portion (54) comprised of the outer sleeve (79). More
particularly, the first coupling
bearing ( 140) is held in the desired position by at least one retaining ring
( 144). Specifically, each
of the outer insert housing ( 110) and the outer sleeve (79) defines a
complementary opposed
bearing shoulder (146) for engagement and abutment with the first coupling
bearing (140). The
first coupling bearing ( I40) is maintained in engagement or abutment with the
opposed bearing
shoulders ( I46) by one or more retaining rings ( 144) extending from one or
both of the inner
surface (68) of the outer insert housing (110) and the outer surface (62) of
the outer sleeve (79).
Further, if required, one or more spacers (148) may be positioned between the
first coupling
bearing (140) and the retaining rings (144) to provide a firm or secure
engagement of the first
coupling bearing (140) with the bearing shoulders (146):
In the preferred embodiment, referring particularly to Figure 7, the second
coupling
bearing ( 142) is positioned more proximate to the second end (74) than the
first end (72) of the
second insert portion (56) between the inner surface (68) of the second insert
portion (56)
comprised of the outer insert housing (110) and the outer surface (62) of the
first insert portion
(54) comprised of the mounting sleeve (78). More particularly, the second
coupling bearing (142)
is seated within a bearing carrier (I50) positioned between the second
coupling bearing (142) and
the mounting sleeve (78). Further, the outer insert housing (110) defines a
bearing shoulder (152)
for engagement or abutment with the second coupling bearing ( 142).
Specifically, the second
coupling bearing (142) is held in the desired position between, and in
engagement with each of,
the bearing shoulder (152) and the bearing carrier (150).
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CA 02482681 2004-09-28'
In addition, in order to enhance or facilitate the engagement of the second
coupling
bearing ( 142) with each of the bearing shoulder ( 1 S2) and the bearing
carrier ( 150), the bearing
carrier ( 1 SO) is preferably urged towards the second coupling bearing (142)
by a biasing
mechanism or device, such as a spring {154). In the preferred embodiment, the
spring (154) is
S comprised of at least one wave spring. Preferably; the outer insert housing
( 110) further defines a
spring shoulder ( 1 S6) such that the spring ( 1 S4) may be positioned between
the spring shoulder
(156) and the bearing carrier (150). Finally, if required; one or more spacers
(158) may be
associated with the spring (154) and positioned between the spring shoulder
(156) and the bearing
carrier (1S0) to enhance or facilitate the action of the spring (154).
Alternately, the second
coupling bearing (142), with or without the bearing earner (1S0), may be held
in the desired
position by one or more retaining rings.
The instrument insert (20) is comprised of the first instrument component
(136) and
the second instrument component (138) for at least one instrument (21).
However, the instrument
insert (20) may include a plurality of first and second instrument components
(136, 138) for a
plurality of instruments (21). In the preferred embodiment, the instrument
insert (20) is comprised
of a first instrument component (136) and a second instrument component (138)
for each of two
instruments (21).
The instrument insert (2U) may be comprised of any type of first and second
instrument components (136, 138) for any type of instrument (21) desired to be
mounted within
the particular tool (22). However, the instrument insert (20) is particularly
configured for use with
an instrument (21) wherein it is desirable for the proper operation or
functioning of the instrument
(21) to maintain the first and second instrument components (136, 138) in a
fixed relative
2S longitudinal position while permitting an amount of relarive longitudinal
movement between the
inner and outer members (24, 26) of the tool (22), and preferably permitting
relative rotation
between the inner and outer members (24, 26). Thus, the instrument (21) may be
of any type
wherein it is desirable to mount the first and second instrument components
(136, 138) within the
tool (22) while maintaining the first and second instrument components (136,
138) in a fixed
relative longitudinal position. In the preferred embodiment, the instrument
(21) is of any type
wherein it is desirable to permit relative rotation between the first and
second instrument
-33-
CA 02482681 2004-09-28
components (136, 138) while maintaining the first and second instrument
components (136, 138)
in a fixed relative longitudinal position.
Far instance, the instrument (21 ) may be comprised of a slip ring assembly (
160) for
transmitting electricity or an electrical signal, comprised of data
communications and / or power,
between the inner member (24) and the outer member (26)~ Thus; the instrument
insert (20)
comprised of the slip ring assembly (160) provides the ability to transfer or
transmit power or data,
such as instructions or information, between the inner and outer members (24,
26) of the tool (22).
Further, the instrument (21) may be comprised of a rotation sensor apparatus
(162) for sensing the
relative rotation of the inner member (24) and the outer member (26). In the
preferred
embodiment, two instruments (21) are associated with the instrument insert
(20), wherein one
instrument (21) is comprised of the slip ring assembly (160) and the other
instrument (21) is
comprised of the rotation sensor apparatus (162).
Preferably, the ability of the instrument (21) to perform its particular
function is not
substantially or significantly affected or impaired by any relative
longitudinal movement between
the inner and outer members (24, 26) of the tool (22) such as may be
experienced by downhole
tools subjected to tension and compression as a result of various borehole
conditions including
vibration, temperature changes and pressure changes and the operation of the
tool (22) including
the weight-on-bit of a drilling tool. The instrument insert (20) is provided
to accommodate or
compensate for the relative longitudinal movement between the inner and outer
members (24, 26)
while maintaining the first and second components (136, 138) of each
instrument (21) in a fixed
relative longitudinal position, thus facilitating its proper operation or
functioning. The instrument
insert (20) particularly compensates for the movement by floating as a unit
within the radial space
(52) between the inner and outer members (24, 26). In particular, the
instrument insert (20) floats,
or is capable of longitudinal movement, relative to at least one of the inner
and outer members (24,
26).
Where the instrument (21) is comprised of the slip ring assembly (160), the
first
instrument component (136) is comprised of one of a conductive slip ring (164)
and a compatible
electrical contact assembly (166) and the second instrument component (138) is
comprised of the
other of the conductive slip ring (164) and the electrical contact assembly
(166). Preferably, for
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CA 02482681 2004-09-28
ease of maintenance and repair of the slip ring assembly (160), the first
instrument component
( 136) is preferably comprised of the conductive slip ring ( 164) and the
second instrument
component (138) is preferably comprised of the compatible electrical contact
assembly (166).
Thus, in the preferred embodiment, the slip ring (164) rotates relative to the
electrical contact
assembly (166) upon the rotation of the first insert portion (54) consequent
to the rotation of the
inner member (24) of the tool (22) relative to the preferably substantially
stationary outer member
(26).
Referring to Figures 3 - 8; the conductive slip ring (164) may be comprised of
any
mechanism, device or structure capable of mounting with the first insert
portion (54) and suitable
for electrical contact with a compatible electrical contact assembly (166).
Preferably, the slip ring
(164) is comprised of a conductive tubular member mounted about the outer
surface (62) of the
first insert portion (54). The slip ring ( 164) may be mounted with the first
insert portion (54) in
any manner and at any position between the first and second ends (64, 64) of
the first insert
portion (54) permitting the slip ring (164) to engage the electrical contact
assembly (166).
In the preferred embodiment, the slip ring (164) is mounted about the outer
surface
{62) of the first insert portion (54), comprised of both the outer sleeve (79)
and the inner mounting
sleeve (78), at a position between the first and second ends (b4, 66). The
tubular slip ring (164)
has an inner circumferential surface ( 168) fvr mounting about the outer
surface (62) of the first
insert portion (54), an outer circumferential surface (170) for engaging the
electrical contact
assembly (166) and opposed first and second ends (172, 174). The outer surface
(62) of the first
insert portion (54) preferably defines an indentation (176) for receipt of the
slip ring (164) therein.
Further, one end of the indentation (l76) is defined by a mounting shoulder
(178) defined by the
outer sleeve (79) of the first insert portion (54) and the other end of the
indentation (176) is
defined by a mounting shoulder ( 180) defined by the mounting sleeve (78) of
the first insert
portion (54).
Thus, to maintain the slip ring in the desired position, the slip ring (164)
is
positioned within the indentation (176) such that the first end (172) of the
slip ring (164) abuts or
engages the mounting shoulder (178) of the outer sleeve (79) and such that the
second end (174) of
the slip ring (164) abuts or engages the mounting shoulder (I80) of the
mounting sleeve (78).
-3 5-
CA 02482681 2004-09-28
Further, as shown in Figure 5, if desired; one or more set screws (182)
extending between the slip
ring (164) and the first insert portion (54) may be used to further secure the
slip ring (164) in the
desired position. The set screw (182) is positioned such that it does not
interfere with the contact
between the outer surface (170) of the slip ring (164) and the electrical
contact assembly (166).
The outer surface ( 170) of the slip ring ( 164) is configured for engagement
with the
electrical contact assembly ( 166). Thus, the outer surface ( 170) may have
any shape or
configuration compatible with the desired electrical contact assembly (166).
However, in the
preferred erilbodiment, the outer surface :(170) is comprised of at least one
circumferential contact
grooves ( 184). In the preferred embodiment, the outer surface ( 170) is
comprised of four
circumferential contact grooves (184), however, more or less circumferential
contact grooves
(184) may be used as desired or required to effect the desired electrical
contact. The
circumferential contact grooves (184) are preferably provided in a spaced,
substantially parallel
arrangement about the outer surface ( 170) and are provided to engage the
electrical contact
assembly (166) to transmit the electricalsignal therebetween.
Finally, the electrical signal or electricity to be transmitted by the slip
ring assembly
( 160) may be provided to or transmitted from the slip ring ( 164) in any
manner suitable for
conducting electricity. In the preferred embodiment, the first insert portion
(54) defines an
electrical conduit (186) therethrough to permit the passage of an electrical
wire through the
electrical conduit (186) for contact with the slip ring (164), as shown in
Figure 4.
Referring particularly to Figures 4, 7 and 8, the electrical contact assembly
(166)
may be comprised of any mechanism, device or structure capable of mounting
with the second
insert portion (56) and suitable for providing an electrical contact with the
slip ring (164).
Preferably, the electrical contact assembly (166) is comprised of at least one
brush block (188)
mounted with the second insert portion (56) to oppose the slip ring (164). As
discussed further
below, the brush block (188) is comprised of at least one, and preferably a
plurality of, electrical
contact brushes or brush leads ( 190). The brush block ( 188) may be mounted
with the second
insert portion (56) in any manner and at any position between. the first and
second ends (72, 74) of
the second insert portion (56) permitting the brush black (188), and
particularly the electrical
-36-
CA 02482681 2004-09-28
contact brushes (190), to electrically contact or engage the contact grooves
(184) of the slip ring
( 164).
In the preferred embodiment, the first insert portion (54) and the second
insert
portion (56) are connected such that the slip ring ( 164) engages the
electrical contact assembly
(166). Further, the brush block (188) is particularly mounted with the outer
insert housing (110)
such that at least a portion of the brush block (188); and particularly the
electrical contact brushes
(190), extend or protrude from the inner surface (68) of the second insert
portion (56). In the
preferred embodiment, the brush block (188) has an inner surface (192) for
protruding or
extending from the inner surface: (68) of he outer insert housixig (110), an
outer surface (194) and
opposed first and second ends ( 196, l 98). Each of the first and second ends
( 196, 198) of the
brush block (188) defines a lip (200) for mounting with the outer insert
housing (110) in the
manner described below.
The outer insert housing (110) defines at least one opening (202) extending
therethrough from the outer surface (70) to the inner surface (6$) of the
second insert portion (56)
for receipt of a brush block (188) therein. Thus, the opening (202) has a size
and configuration
compatible with receipt of the brush block (188) therein such that the inner
surface (192) of the
brush block (188) and the electrical contact brushes (190) are capable of
protruding or extending
from the inner surface (68) of the second insert portion (56). Further,
although the brush block
(188) may be mounted within the opening (202) in any manner, each of a first
side (204) and a
second opposed side (206) of the opening (202) preferably define a lip (208)
compatible with the
lip (200) at each end (196, 198) of the brush block (188).
Specifically, the brush block (188) is positioned within the opening (202)
such that
the lips (200) on the first and second ends (196, 198) of the brush block
(188) engage the
compatible lips (208) on the first and second sides (204, 206) of the opening
(200) in the outer
insert housing (110). Accordingly, the brush block (I88) is suspended in the
opening (202) in
opposition to the slip ring ( 164). Further, in order to ensure that the lips
(200, 208) remain in
engagement, one or more screws (2I0) may extend through the lips (200, 208).
In the preferred
embodiment, four set screws (210) are provided. Two set screws (210) fasten
the lips (200, 208)
together at the engagement of the first end ( 196) of the brush block ( 188)
and the first side (204) of
-3 7-
CA 02482681 2004-09-28
the opening (202). Similarly, two set screws (210) fasten the Iips (200, 208)
together at the
engagement of the second end (198) of the brush block (188) and the second
side (206) of the
opening (202). This manner of mounting the brush block (188) provides easy
access to and
removal of the brush block (188) in the event that repairs or replacement are
required.
The electrical contact brushes ( 190) are configured for engagement or
electrical
contact with the contact grooves ( 184) of the slip ring ( 164). Thus, the
electrical contact brushes
(190) may have any shape or confguration compatible with the contact grooves
(184). However,
in the preferred embodiment; four circumferential contact grooves (184) are
provided.
Accordingly, the brush block (188) is comprised of at least four electrical
contact brushes (190) or
contact leads to engage the contact grooves ( 184) in order to transmit the
electrical signal
therebetween. However, more or less electrical contact brushes (190) may be
provided as required
to provide the desired electrical contact.
Each electrical contact brush ( 190) is comprised of at least one and
preferably a
plurality of fine conductive wires having an inner end (2 i 2) for engaging or
contacting a single
contact groove (184) and an opposed outer end (214). Each contact brush (190)
extends through,
and is mounted or fastened within, an opening or passage in the brush block
(188) extending
between the outer surface (194) and the inner surface (192) of the brush block
(188). The inner
end (212) extends from the inner surface (192) of the brush block (188) for
engaging the contact
groove (184). The outer end (2L4) extends from the outer surface (194) of the
brush block (188)
to provide an electrical contact point for the brush block (188) as discussed
below. If desired, the
brush block ( 188) or the contact brushes ( 190) may be spring-loaded or
otherwise urged or biased
in the direction of the contact grooves ( 184) to facilitate the electrical
contact between the outer
2S ends (2I4) of the contact brushes (190) and the contact grooves (184).
Finally, the electrical signal or electricity to be transmitted by the slip
ring assembly
(160) may be provided to or transmitted from the electrical contact assembly
(166), and
particularly the brush block (188), in any manner suitable fox conducting
electricity. In the
preferred embodiment, an electrical wire is connected with the outer ends
(214) of the electrical
contact brushes ( 190). Further, the second insert portion (56) defines an
electrical conduit (216)
-3 8-
CA 02482681 2004-09-28
therethrough to permit the passage of the electrical wire through the
electrical conduit (216) for
connection with the electrical contact brushes (190) as described and as shown
in Figure 4.
Where the instrument (21 ) is comprised of the rotation sensor apparatus (
162), the
first instrument component (136) is preferably comprised of one of at least
one magnet {218) and
at least one compatible magnetic sensor (220) and the second instrument
component (138) is
preferably comprised of the other of the at least one magnet (218) and the at
least one compatible
magnetic sensor (220). In the preferred embodiment, the first instrument
component (136) is
comprised of at least one magnet (218) and the second instrument component
(138) is preferably
comprised of a compatible magnetic sensor (220). Thus, in the preferred
embodiment, the magnet
(218) rotates relative to the magnetic sensor (220) upon the rotation of the f
rst insert portion (54)
consequent to the rotation of the inner member (24) of the tool (22) relative
to the preferably
substantially stationary outer member (26).
Referring particularly to Figure 6, one or more magnets (218) may be mounted a
spaced distance apart about the circumferential inner surface (60) of the
first insert portion (54).
In the preferred embodiment, at plurality of magnets {218) are mounted about
the circumference of
the outer surface (62) of the first insert portion (54) comprised of the
mounting sleeve (78) at a
position or location within the second insert portion (54). In particular, the
magnets (218) are
mounted with the mounting sleeve (78) to be positioned at, adjacent or in
proximity to the second
end (74) of the second insert portion (56) comprised of the outer insert
housing {110). Each
magnet (2 i 8) may be mounted with the mounting sleeve (78) in any manner
permitting the magnet
sensor (220) to sense the proximity of the magnet (218). Further, any type or
configuration of
magnet (218) capable of mounting within the first insert portion (54) and
compatible with the
magnetic sensor (220) may be used.
In the preferred embodiment, the magnet (218) is mounted within an indentation
or
cavity (222) defined by the outer surface (62) of the mounting sleeve (78) for
each of the magnets
(218). The indentation (222) is sized or configured for close receipt of the
magnet (218) therein
such that the magnet {218) is retained in the indentation (222) during use of
the rotation sensor
apparatus ( 162). Where required, other retaining or fastening mechanisms or
devices may be used
to retain, fasten or affix the magnet (218) within the indentation (218).
-3 9-
CA 02482681 2004-09-28
The magnetic sensor (220} may be comprised of any mechanism, device or
structure
capable of mounting with the second insert portion (56) and suitable for and
capable of sensing the
proximity of the magnet (218) to the magnetic sensor (220). Preferably, the
magnetic sensor (220)
is comprised of a position switch assembly used for determining the rotations
per minute of the
inner member (24). Any conventional or known magnet (218) and compatible
position switch
assembly (220) may comprise the rotation: sensor apparatus (162).
Referring to Figure 3 - 7, in the preferred embodiment, the first insert
portion (54)
and the second insert portion (56) are connected such that the magnetic sensor
(220) is capable of
sensing the proximity of the magnet (218) to the magnetic sensor (220).
Further, the magnetic
sensor (220) is mounted with the outer insert housing (110) such that the
magnetic sensor (220)
accesses or communicates with the inner surface (68) of the second insert
portion (56). Further,
the magnetic sensor (220) is positioned at, adjacent or in proximity to the
second end (74) of the
second insert portion (56) comprised of the outer insert housing (110). As a
result, upon the
rotation of the mounting sleeve (78) relative to the outer insert housing
(110), the magnet (218)
mounted within the mounting sleeve (78) is moved or rotated in a path which
crosses or intersects
with the location of the magnetic sensor (220) such that the magnet (218)
opposes the magnetic
sensor (220) in order to permit the magnetic sensor (220) to sense the
proximity of the magnet
(218) to the magnetic sensor (220).
In the preferred embodiment; the magnetic sensor (220) is mounted within a
cavity,
orifice or opening (224) defined by the outer insert housing (110) for receipt
of the magnetic
sensor (220) therein. The cavity (224) may extend through the outer insert
housing (110) from the
outer surface (70) to the inner surface (68) of the second insert portion (56)
for receipt of the
magnetic sensor (220). In any event, the cavity (224) is particularly sized or
configured for close
receipt of the magnetic sensor (220) therein such that the magnetic sensor
(220) is retained in the
cavity (224) during use of the rotation sensor apparatus (162)., Where
required, other retaining or
fastening mechanisms or devices may be used to retain, fasten or affix the
magnetic sensor (220)
within the cavity (224).
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CA 02482681 2004-09-28
Preferably, the magnetic sensor (220) has an inner end (226) mounted proximate
to
the inner surface (68) of the second insert portion (56) for sensing the
magnet (218) and an
opposed outer end (228). The outer end (228) is preferably mounted proximate
to the outer
surface (70) of the second insert portion (56) to provide an electrical
contact point for the magnetic
sensor (220). An electrical signal or electricity may be transmitted from or
to the magnetic sensor
(220) in any manner suitable for conducting electricity. However, in the
preferred embodiment, an
electrical wire is connected with the outer end (228) of the rnagnetic sensor
(220). Further, the
electrical conduit (216) defined by the second insert portion (56) preferably
permits the passage of
the electrical wire through the electrical conduit {216) fox connection with
the magnetic sensor
(220) as described.
Further, if required to ensure the proper operation of the instrument insert
(20), the
instrument insert (20) or the tool (22) may include one or more seal
assemblies (not shown),
preferably a rotary seal assembly, for containing a lubricant within the
instrument insert (20) and,
if desired, the surrounding components' of the tool (22) in which the
instrument insert (20) is
mounted. Further, the rotary seal assemblies also preferably inhibit the
passage of undesirable
fluids, such as drilling fluid, into the instrument insert (20) and, if
desired, the surrounding
components of the tool (22). Any known or conventional seal assemblies may be
used.
Finally, the present invention is further directed at improvements or
innovations to
the slip ring assembly (160) which are particularly shown in Figures 9 - 15.
In the preferred
embodiment of the instrument insert (20) described above, the slip ring
assembly (160) as
previously described is utilized. However, where desirable or necessary to
facilitate the proper
functioning or operation of the slip ring assembly (160), the slip ring
assembly (160) may include
one or more of the innovations to the slip ring assembly (160) as described
further below and as
shown in Figures 9 - 15. In this instance, the slip ring assembly (160) with
the further features is
preferably mounted within the instrument insert (20) in the manner previously
described.
As well as utilizing the slip ring assembly (164) in the instrument insert
(20), the
slip ring assembly (160) may also be' utilized in any other application in
which a slip ring
assembly is desirable or is conventionally utilized for the transmission of
electricity or an
electrical signal between two components rotating relative to each other. In
other words, the slip
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CA 02482681 2004-09-28
ring assembly (160) having one or more of the further features described
herein may be utilized in
applications or tools other than as a part or component of, ar in conjunction
with, the instrument
insert (20).
S Referring to Figures 9 - 15, as described above, the slip ring assembly
(160) is
provided for transmitting electricity or an electrical signal, comprised of
data communications and
/ or power, between components of the shp ring assembly (160) rotating
relative to each other.
Thus, the slip ring assembly ( 160) provides the ability to transfer or
transmit power or data, such
as instructions or information, between the slip ring ( 164) and the
electrical contact assembly
(166).
As well, the slip ring assembly (I60) is preferably adapted to compensate or
adjust
for, or counteract, the potentially negative impact of high pressure and high
vibration
environments downhole which may interfere with or impede the proper
functioning or operation of
the slip ring assembly ( 160). More particularly, the slip ring assembly (
160) preferably
compensates or adjusts for, or counteracts, any separation of the slip ring
(164) and the electrical
contact assembly (166) or axial or lateral vibrational movement of the slip
ring (164) relative to
the electrical contact assembly (166). Thus, the slip ring assembly (160)
preferably assists with or
facilitates the maintenance of the desired engagement or electrical contact
between the slip ring
( 164) and the electrical contact assembly ( 166).
Referring to Figures 9 - 1 l, as stated, the slip ring ( 164) may be comprised
of any
mechanism, device or structure suitable for electrical contact with the
compatible electrical contact
assembly (166). However, the slip ring (164) is preferably comprised of a
conductive tubular
member. The outer surface (170) of the slip ring (164) defines the
circumference of the slip ring
( 164) for engaging the electrical contact assembly ( 166). The outer surface
( 170) of the slip ring
(164) is configured for engagement with the electrical contact assembly (166).
More particularly,
the slip ring (164) defines an electrical contact groove (184) extending about
the circumference of
the slip ring ( 164) or about the outer circumferential surface ( 170).
Figures 9 - 11 show the slip ring (164) defining a single electrical contact
groove
(184). However, the slip ring (164) may define any number of electrical
contact grooves (184) as
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CA 02482681 2004-09-28
desired or required to transmit the desired electricity or electrical signal
or signals through a
desired or required number of electrical channels. Thus, for instance, as
described previously and
as shown in Figures 1 - 8, the slip ring ( 166) may define four electrical
contact grooves ( I 84)
about the circumference thereof, although more or less circumferential
electrical contact grooves
(184) may be used as desired or required to effect the desired electrical
contact.
Finally, the electrical signal or electricity is preferably provided to or
taransmitted
from the slip ring ( 164) in the same manner as previously described for the
slip ring assembly
(I60) as shown in Figures I - 8. Specifically, at least one electrical conduit
(not shown) is
preferably provided to permit the passage of one or more electrical wires (not
shown )
therethrough for contact with the slip ring (164).
Referring to Figures 9 - I5, the electrical contact assembly (I66) is
comprised of at
least one electrical contact (187) for engaging the slip ring (164). However,
in order to enhance or
facilitate the maintenance of the electrical contact between the slip ring
(164) and the electrical
contact assembly (166), the electrical contact assembly (I66) is preferably
comprised of a plurality
of electrical contacts (187) for engaging the slip ring (164). As shown in
Figures 9 - l l, in the
preferred embodiment, the electrical contact assembly (166) is comprised of
three electrical
contacts ( 187): Further, the plurality of electrical contacts ( 187) is
preferably spaced about the
circumference of the slip ring ( 164). More preferably, the plurality of
electrical contacts ( 187) is
spaced substantially evenly about the circumference of the slip ring ( 164).
Each of the plurality of electrical contacts (187) is provided for engaging
the
electrical contact groove (184) on the slip ring (I64) as shown in Figures 9 -
11. The plurality of
electrical contacts (187) engage a single electrical contact groove (184) in
order to assist, facilitate
or maintain the engagement of at least one electrical contact (187) with the
electrical contact
groove (I84) at all times during use. In other words, in the event of any
misalignment of the slip
ring ( 164) and electrical contact assembly ( 166), such as axial or lateral
or vibrational movement
of the slip ring ( 164) relative to the electrical contact assembly ( 166),
one or more, and preferably
at least two, electrical contacts (187) remain engaged with the electrical
contact groove (184).
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CA 02482681 2004-09-28
Where the slip ring ( I64) is comprised of greater than one electrical contact
groove
(184), at least one electrical contact (187) is provided for engaging each
electrical contact groove
(184). Preferably, a plurality of electrical contacts (187) is spaced about
the slip ring (164) for
engaging each of the plurality of electrical contact grooves ( 184).
Further, the electrical contact assembly (166) is preferably comprised of at
least one
brush block (I88), as described above in relation to Figures 1 - 8, wherein
the electrical contact
(187) is carried by the brush block (188). More preferably, the electrical
contact assembly (166) is
comprised of a plurality of brush blocks (I88), wherein the electrical
contacts (187) are carried by
the brush blocks (188) . In the preferred embodiment, as hawn in Figures 9 -
11, the electrical
contact assembly (166) is comprised of three brush blocks (188): In this case,
a single electrical
contact (187) is carried by each of the brush blocks (188). However, if
desired or required for a
particular application or where the slip ring (I64) defines a plurality of
electrical contact grooves
(184), a plurality of electrical contacts (I87) may be earned by each of the
brush blocks (188).
The electrical contact (187) may comprise a portion of the brush block (188)
or the
electrical contact (187) may be mounted, affixed or otherwise carried by the
brush block (188).
However, as indicated above, in the preferred embodiment and referring
particularly to Figure I5,
the electrical contact (187) is carried by the brush block (188). The
electrical contact (187) may
be carried by the brush block (188) in any suitable manner permitting the
electrical contact (187)
to engage the electrical contact groove (184).
The slip ring (164) is adapted to rotate relative to the electrical contact
assembly
(166). Thus, the slip ring (164) rotates relative to the brush blocks (188)
comprising the electrical
contact assembly (166) and the electrical contact (187) carried thereby. As a
result, each of the
electrical contacts (187) is comprised of a leading or upstream side (230) and
a trailing or
downstream side (232) as shown in Figures 14 - 15.
In addition, the electrical contact assembly (166) is preferably comprised of
an
urging mechanism (234) for urging the electrical contact (187) toward
engagement with the slip
ring (164) and particularly the electrical contact groove (184). The urging
mechanism (234) may
be comprised of any biasing de~rice or mechanism capable of and suitable for
urging the electrical
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CA 02482681 2004-09-28
contact ( 187) toward the slip ring ( 164}. However, preferably, the urging
mechanism (234) is
comprised of a spring (236). Further, in the preferred embodiment; wherein the
electrical contact
assembly (166) is comprised of a plurality of electrical contacts (187), the
urging mechanism (234)
is associated with each of the electrical contacts (187) for urging the
electrical contacts (187)
toward engagement with the electrical contact groove ( 184): More
particularly, the urging
mechanism (234) is preferably comprised of a plurality of springs (236) so
that one of the springs
(236) is associated with each of theelectrical contacts (187):
As a result, at least one spring (236) is preferably associated with each
brush block
(188). In the event that a single electrical contact (187) is carried by the
brush block (188), a
single spring (236) is preferably provided for urging the electrical contact
(187) toward the
electrical contact groove ( 184). However, in the event that a plurality of
electrical contacts ( 187)
is carried by the brush block (188), a single spring (236) may be provided for
urging the electrical
contacts (187) together as a unit toward the electrical contact groove (184).
Alternately, a
plurality of springs (236} may be provided for urging the electrical contacts
(187) such that at least
one spring (236) is associated with each of the electrical contacts (187).
The spring (236) may be positioned or located upon or mounted, affixed or
fastened
with the brush block (188) in any manner permitting the spring (236) to urge
the electrical contact
(187) toward the slip ring (164). Referring to Figures 9 - 15, the brush block
(188} is comprised of
an upper or outermost surface (238) and an opposed lower or innermost surface
(240). Preferably,
the electrical contact ( 187) is associated with or extends from the lower
surface (240) of the brush
block (188) for engagement with the adjacent slip ring (164). Thus, for
instance, the spring (236)
may be associated with, and act upon, the upper surface (238) of the brush
block (188) to urge the
brush block (188) towards the slip ring (i64}.
However, referring to Figure 15, the spring (236) is preferably disposed
between the
brush block ( 188) and the electrical contact ( l87) such that the spring
(236) urges the electrical
contact ( 187) toward engagement with the slip ring ( 164). In i:he preferred
embodiment, the brush
block (188), and particularly the lower surface (240) thereof, defines a
cavity (242) or recess for
receipt of the electrical contact (187). Specifically, a portion of the
electrical contact (187) is
slidably received within the cavity (242) such that the electrical contact
(I87) extends from the
-45-
CA 02482681 2004-09-28
lower surface (240) of the brush block (188) for engagement with the
electrical contact groove
(184). The spring (236) is preferably contained or positioned within the
cavity (242) between the
body of the brush block (188) and the portion of the electrical contact (187)
slidably received in
the cavity (242). Thus, as seen in Figure 15, the spring (236) acts between
the brush block (188)
and the electrical contact ( 187) to urge the electrical contact out of or
away from the lower surface
(240) of the brush block (188). The spring (236) therefore provides a
relatively constant positive
contact force between the electrical contact ( 187) and the electrical contact
groove ( 184).
If desired, a retaining mechanism (not shown ) rnay be provided to prevent or
inhibit the complete removal of the electrical contact (187) from the cavity
(242).
Further, the spring (236) is selected to provide a spring force capable of
urging the
electrical contact (187) into engagement with the electrical contact groove
(184), while not
incurring or causing any significant or substantial damage to the electrical
contact (187) as a result
of the engagement. As well, the spring force must not substantially interfere
with or impede the
rotation of the slip ring (164) relative to the brush block (188). As stated,
the spring (236)
preferably provides a relatively constant positive contact force between the
electrical contact (187)
and the electrical contact groove (184).
In addition, the slip ring (164) is preferably comprised of a relatively hard
conductive material with anti-galling properties, such as Beryllium Copper.
The electrical contact
(187) is preferably comprised of a relatively softer material as compared with
the slip ring (164).
Thus, the electrical contact (187) and the brush block (188) are preferably
designed as the wear
component of the slip ring assembly ( 160).
In addition, as discussed with respect to Figures 1 - 8, each of the
electrical contacts
(187) is preferably comprised of at least one, and more preferably a plurality
of, electrical contact
brushes or brush leads (not shown in Figures 9 - 15). The electrical contact
brushes or brush leads
extend from the brush block (188) as discussed above for engagement with the
electrical contact
groove ( 184). The electrical contact brushes are configured for engagement or
electrical contact
with the contact grooves (184) of the slip ring (I64). The number of
electrical contact brushes
may be selected to provide the desired electrical contact and to provide the
desired transmission or
-46-
CA 02482681 2004-09-28
communication of electricity or electrical signals thereby. The electrical
contact brushes may be
mounted or associated with the brush block (188) in the same manner as
described previously in
relation to Figures 1 - 8.
Further, the electrical signal or electricity to be transmitted by the slip
ring assembly
(160) may be provided to or transmitted from the electt~ical contact assembly
(166), and
particularly the brush block (188), in any manner suitable for conducting
electricity, as described
previously. For instance, the brush block (188) may define one or more
conduits (not shown) for
the passage of an electrical wire (not shown ) therethrough for connection
with the electrical
contact ( 187).
Finally, the electrical contact assembly (166) is preferably further comprised
of a
wiper (244) for extending within the electrical contact groove (184) to
inhibit a fluid from passing
through the electrical contact groove (184). The wiper (244) is preferably
associated with the
electrical contact ( 187). Thus, where the electrical contact assembly ( 166)
is comprised of a
plurality of electrical contacts (187), the wiper (244) is preferably
associated with each of the
electrical contacts ( 187) for extending within the electrical contact groove
( 184) to inhibit a fluid
from passing through the electrical contact groove (184): As well, where the
slip ring (164)
defines a plurality of electrical contact grooves (184), the wiper (244)
preferably extends within at
least one electrical contact groove ( 184), and preferably extends within each
of the plurality of
electrical contact grooves (184) to inhibit a fluid from passing through the
electrical contact
grooves (184).
The wiper (244) as described herein is provided to reduce the flow of fluid
between
the electrical contact (187) and the electrical contact groove {184); which
flow may tend to
produce a lifting pressure or a hydro-planing effect therebetween. A
significant or substantial
lifting pressure or hydro-planing effect may interfere with or impede the
electrical engagement
between the electrical contact (187) and the electrical contact groove (184}.
Preferably, as shown in Figures 9 - 15, the wiper {244) is located or
positioned on
the brush block (188). Where the electrical contact assembly (166) is
comprised of greater than
one brush block (188), a wiper (244) is preferably located or positioned on
each brush block (188).
-47-
CA 02482681 2004-09-28
Therefore, each brush block ( 188) and wiper (244) are preferably
substantially similar. Thus, the
following description relating to a single electrical contact ( I 87) and
wiper (244) will be the
substantially similar in the case of a plurality of electrical contacts (187)
and a plurality of
associated wipers (244).
More particularly, the wiper (244) is preferably positioned adjacent to the
leading or
upstream side (230) of the electrical contact (187). In addition, the wiper
(244) is preferably
located on the brush block (188). The wiper (244) may be comprised of a wiper
mechanism,
structure or device, as described herein, which is attached, mounted or
fastened with the brush
block (188). However, in the preferred embodiment, the wiper (244) is
integrally formed with the
brush block (244), particularly the lower surface (240) thereof
Further, the wiper (244) may be comprised of any mechanism, structure or
device
capable of inhibiting a fluid from passing through the electrical contact
groove ( 184). However,
the wiper (244) is preferably comprised of an elongated rib (246) which
extends parallel to the
electrical contact groove (184). As stated, the elongated rib (246) is
preferably integrally formed
with the lower surface (240) of the brush block (244), adjacent the upstream
side (230). Further,
the elongated rib (246) is sized and configured to be compatible with the
electrical contact groove
(184) such that a desired amount of fluid or fluid flow is inhibited from
passing therethrough. The
size and configuration of the elongated rib (246) and the desired resulting
inhibition of the fluid
flow will be selected to reduce or prevent any undesirable lifting forces or
hydro-planing as
described above.
Where the slip ring (164) defines greater than one electrical contact groove
(184),
the wiper (244) is preferably comprised of a plurality of elongated ribs
(246), wherein an
elongated rib (246) is provided for each electrical contact groove (184) to
inhibit the passage or
flow of fluid therethrough.
Further, in the preferred embodiment, the wiper (244) is preferably comprised
of an
upstream wiper member (248) positioned adjacent to the upstream side (230) of
the electrical
contact (187). However, the wiper (244) may be further comprised of a
downstream wiper
member (250) positioned adjacent to the downstream side (232) of the
electrical contact (187).
-48-
CA 02482681 2004-09-28
Thus, where the wiper (244) is comprised of the elongated rib (246), the
upstream wiper member
(248) is comprised of an upstream elongated rib (252) which extends
substantially parallel to the
electrical contact groove (184) and the downstream wiper member (250) is
comprised of a
downstream elongated rib (254) which extends substantially parallel to the
electrical contact
groove (184). As discussed above, each of the upstream and downstream
elongated ribs (252,
254) is sized and configured to be compatible with the electrical contact
groove (184) such that a
desired amount of fluid or fluid flow is inhibited from passing therethrough.
Finally; in this document, the word "comprising" is used in its non-limiting
sense to
mean that items following the word are included, but items not specifically
mentioned are not
excluded. A reference to an element by the indefinite article "a" does not
exclude the possibility
that more than one of the element is present, unless the context clearly
requires that there be one
and only one of the elements.
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