Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02569070 2006-12-15
BEARING PRE-LOAD ASSEMBLY FOR A STEERABLE ROTARY DRILLING
DEVICE
FIELD OF INVENTION
The present invention relates to a steerable rotary drilling device and a
method
for directional drilling using a rotary drilling string. Further, the present
invention relates to a
drilling direction control device and a method for controlling the direction
of rotary drilling.
BACKGROUND OF INVENTION
Directional drilling involves varying or controlling the direction of a
wellbore as
it is being drilled. Usually the goal of directional drilling is to reach or
maintain a position
within a target subterranean destination or formation with the drilling
string. For instance, the
drilling direction may be controlled to direct the wellbore towards a desired
target destination,
1-5 to control the wellbore horizontally to maintain it within a desired
payzone or to correct for
unwanted or undesired deviations from a desired or predetermined path.
Thus, directional drilling may be defined as deflection of a wellbore along a
predetermined or desired path in order to reach or intersect with, or to
maintain a position
within, a specific subterranean formation or target. The predetermined path
typically includes a
depth where initial detlection occurs and a schedule of desired deviation
angles and directions
over the remainder of the wellbore. Thus, deflection is a change in the
direction of the wellbore
from the current wellbore path.
It is often necessary to adjust the direction of the wellbore frequently while
directional drilling, either to accommodate a planned change in direction or
to compensate for
unintended or unwanted deflection of the wellbore. Unwanted deflection may
result from a
variety of actors, 111C1Lldlllg the characteristics of the formation being
drilled, the makeup of the
bottomhole drilling assembly and the manner in which the wellbore is being
drilled.
Deflection is measured as an amount of deviation of the wellbore from the
cul-rent wellbore path and is expressed as a deviation angle or hole angle.
Commonly, the
initial wellbore path is in a vertical direction. Thus, initial deflection
often signifies a point at
which the wellbore has deflected off vertical. As a result, deviat10I1 IS
COIn1110111y expressed as
an angle in degrees from the vertical.
CA 02569070 2006-12-15
Various teclmiques may be used for directional drilling. First, the drilling
bit
may be rotated by a dowlW ore motor which is powered by the circulation of
fluid supplied from
the surface. This technique, sometimes called "sliding drilling", is typically
used in directional
drilling to effect a change in direction of the wellbore, such as the building
of an angle of
deflection. However, various problems are often encountered with sliding
drilling.
For instance, sliding drilling typically involves the use of specialized
equipment
in addition to the downhole drilling motor, including bent subs or motor
housings, steering
tools and nomnagnetic drill string components. As well, the downhole motor
tends to be
subject to wear given the traditional, elastomer motor power section.
Furthermore, since the
drilling string is not rotated during sliding drilling, it is prone to
sticking in the wellbore,
particularly as the angle of deflection of the wellbore from the vertical
increases, resulting in
reduced rates of penetration of the drilling bit. Other traditional problems
related to sliding
drilling include stick-slip, whirling, differential sticking and drag
problems. For these reasons,
and due to the relatively high cost of sliding drilling, this technique is not
typically used in
directional drilling except where a change in direction is to be effected.
Second, directional drilling may be accomplished by rotating the entire
drilling
string from the surface, ~1~L11C11 111 turn rotates a drilling bit connected
to the end of the drilling
string. More specifically, in rotary drilling, the bottomhole assembly,
including the drilling bit,
is connected to the drilling string which is rotatably driven from the
surface. This technique is
relatively inexpensive because the use of specialized equipment such as
downhole drilling
motors can usually be kept to a minimum. In addition, traditional problems
related to sliding
drilling, as discussed above, are often reduced. The rate of penetration of
the drilling bit tends
to be greater, while the wear of the drilling bit and casing are often
reduced.
However, rotary drilling tends to provide relatively limited control over the
direction or orientation of the resulting wellbore as compared to sliding
drilling, particularly in
extended-reach wells. Thus rotary drilling has tended to be largely used for
non-directional
drilling or directional drilling where no change in direction is required or
intended.
Third, a CO111b111at1011 Of rotary and sliding drilling may be performed.
Rotary
drilling will typically be performed until such time that a variation or
change in the direction of
the wellbore is desired. The rotation of the drilling string is typically
stopped and sliding
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drilling, through use of the dowlW ole motor, is commenced. Although the use
of a combination
of sliding and rotary drilling may permit satisfactory control over the
direction of the wellbore,
the problems and disadvantages associated with sliding drilling are still
encountered.
Some attempts have been made in the prior art to address these problems.
Specifically, attempts have been made to provide a steerable rotary drilling
apparatus or system
for use in directional drilling. However, none of these attempts have provided
a fully
satisfactory solution.
United Kingdom Patent No. GB 2,172,324 issued July 20, 1988 to Cambridge
Radiation Technology Limited ("Cambridge") utilizes a control module
comprising a casing
having a bearing at each end thereof for supporting the drive shaft as it
passes through the
casing. Further, the control module is comprised of four flexible enclosures
in the form of bags
located in the amular space between the drilling string and the casing to
serve as an actuator.
The bags actuate or control the direction of drilling by applying a radial
force to the drive shaft
within the casing such that the drive shaft is displaced laterally between the
bearings to provide
a desired curvature of the drive shaft. Specifically, hydraulic fluid is
selectively conducted to
the bags by a pump to apply the desired radial force to the drilling string.
Thus, the direction of the radial force applied by the bags to deflect the
drive
shaft is controlled by COlltr011111g the application of the hydraulic pressure
from the pump to the
bags. Specifically, one or two adjacent bags are individually fully
pressurized and the two
remaining bags are depressurized. As a result, the drive shaft is deflected
and produces a
curvature between the bearings at the opposing ends of the casing of the
control module. This
controlled curvature controls the drilling direction.
United Kingdom Patent No. GB 2,172,325 issued July 20, 1988 to Cambridge
and United Kingdom Patent No. GB 2,177,738 issued August 3, 1988 to Cambridge
describe
the use of flexible enclosures in the form of bags in a similar manner to
accomplish the same
purpose. Specifically, the drilling string is supported between a near bit
stabilizer and a far bit
stabilizer. A control stabilizer is located between the near and far bit
stabilizers for applying a
radial force to the drilling stI'illg V'lthlil the control stabilizer such
that a bend or curvature of
the drilling string is produced between the near bit stabilizer and the far
bit stabilizer. The
control stabilizer is comprised of four bags located in the annular space
between a housing of
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the control stabilizer and the drilling string for applying the radial force
to the drilling string
within the control stabilizer.
United Kingdom Patent Application No. GB 2,307,537 published May 28, 1997
by Astec Developments Limited describes a shaft alignment system for
controlling the direction
of rotary drilling. Specifically, a shaft, such as a drilling string, passes
through a first shaft
support means having a first longitudinal axis and a second shaft support
means having a
SeCOlld lOllgltlldlllal axis. The first and second shaft support means are
rotatably coupled by
bearing means having a bearing rotation axis aligned at a first non-zero angle
with respect to
the first longitudinal axis and aligned at a second non-zero angle with
respect to the second
longitudinal axis. As a result, relative rotation of the first and second
shaft support means about
their respective longitudinal axes varies the relative angular aligmnent of
the first and second
longitudinal axes.
The shaft passing through the shaft aligmnent system is thus caused to bend or
curve in accordance with the relative angular alignment of the first and
second longitudinal
axes of the first and second shaft support means. The shaft may be formed as a
unitary item
with a flexible central section able to accommodate the desired curvature or
it may be
comprised of a coupling, such as a universal joint, to accommodate the desired
curvature.
United States of America Patent No. 5,685,379 issued November 11, 1997 to
Bal-r et. al., United States of America Patent No. 5,706,905 issued January
13, 1998 to Barr et.
al. and United States of America Patent No. 5,803,185 issued September 8, 1998
to Barr et. al.
describe a steerable rotary drilling system including a modulated bias unit,
associated with the
drilling bit, for applying a lateral bias to the drilling bit in a desired
direction to control the
direction of drilling. The bias unit is comprised of three equally spaced
hydraulic actuators,
each having a movable thrust member which is displaceable outwardly for
engagement with the
wellbore. The hydraulic actuators are operated in succession as the bias unit
rotates during
rotary drilling, each in the same rotational position, so as to displace the
bias unit laterally in a
selected direction.
PCT International Application No. PCT/LJS98/24012 published May 20, 1999 as
No. WO 99/24688 by Telejet Technologies, Inc. describes the use of a
stabilizer assembly for
directional drilling. More particularly, a stabilizer sub is connected with
the rotary drilling
string such that the stabilizer sub remains substantially stationary relative
to the wellbore as the
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drilling string rotates. The stabilizer sub includes a fixed upper stabilizer
and an adjustable
lower stabilizer. The lower adjustable stabilizer carries at least four
stabilizer blades which are
independently radially extendable froth the body of the stabilizer sub for
engagement with the
wellbore.
Each stabilizer blade is actuated by a motor associated with each blade.
Because
each stabilizer blade is provided with its own motor, the stabilizer blades
are independently
extendable and retractable with respect to the body of the stabilizer sub.
Accordingly, each
blade may be selectively extended or retracted to provide for the desired
drilling direction.
United States of America Patent No. 5,307,885 issued May 3, 1994 to Kuwana
et. al., United States of America Patent No. 5,353,884 issued October 11, 1994
to Misawa et. al.
and United States of America Patent No. 5,875,859 issued March 2, 1999 to
Ikeda et. al. all
utilize harnionic drive mechanisms to drive rotational members supporting the
drilling string
eccentrically to deflect the drilling string and control the drilling
direction.
1\~Tore particularly, Kwvana et. al. describes a first rotational ammlar
member
colmected with a first hanuonic drive mechanism a spaced distance from a
second rotational
annular member connected with a second harmonic drive mechanism. Each
rotational aluuular
member has an eccentric hollow portion which rotates eccentrically around the
rotational axis
of the atmular member. The drilling string is supported by the ituuer surfaces
of the eccentric
portions of the annular members. Upon rotation by the harmonic drive
mechanisms, the
eccentric hollow portions are rotated relative to each other in order to
deflect the drilling string
and change the orientation of the drilling string to the desired direction.
Specifically, the
orientation of the drilling string is defined by a straight line passing
through the centres of the
respective hollow portions of the annular members.
Misawa et. al. describes harmonic drive mechanisms for driving first and
second
rotatable annular members of a double eccentric mechanism. The first rotatable
annular
member defines a first eccentric inner circumferential surface. The second
rotatable annular
member, rotatably supported by the first eccentric inner circumferential
surface of the first
annular member, def nes a second eccentric inner circumferential surface. The
drilling string is
supported by the second eccentric itmer circumferential surface of the second
annular member
and uphole by a shaft retaining mechanism. Thus, upon actuation of the
harmonic drive
nleCha111SI11S, the first and second annular members are rotated resulting in
the movement of the
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center of the second eccentric circumferential surface. Thus the drilling
string is deflected from
its rotational centre in order to orient it in the desired direction.
Upon deflection of the drilling string, the fulcrum point of the deflection of
the
drilling string tends to be located at the upper supporting mechanism, i.e.
the upper shaft
retaining mechanism. As a result, it has been found that the drilling string
may be exposed to
excessive bending stress.
Similarly, Ikeda et. al. describes harmonic drive mechanisms for driving first
and
second rotatable ammlar members of a double eccentric mechanism. However,
Ikeda et. al.
requires the use of a flexible joint, such as a universal joint, to be
connected into the drilling
string at the location at which the maximum bending stress on the drilling
string takes place in
order to prevent excessive bending stress on the drilling string. Thus, the
flexible joint is
located adjacent the upper supporting mechanism. Upon deflection of the
drilling string by the
double eccentric mechanism, the deflection is absorbed by the flexible joint
and thus a bending
force is not generated on the drilling string. Rather, the drilling string is
caused to tilt downhole
of the double eccentric mechanism. A fulcn.tm bearing downhole of the double
eccentric
mechanism functions as a thrust bearing and serves as a rotating centre for
the lower portion of
the drilling string to accommodate the tilting action.
However, it has been found that the use of a flexible or articulated shaft to
avoid
the generation of excessive bending force on the drilling string may IlOt be
preferred.
Specifically, it has been found that the articulations of the flexible or
articulated shaft may be
prone to failure.
Thus, there remains a need in the industry for a steerable rotary drilling
device or
drilling direction control device for use with a rotary drilling string, and a
method for use in
rotary drilling for controlling the drilling direction, which provide
relatively accurate control
over the trajectory or orientation of the drilling bit during the drilling
operation, while also
avoiding the generation of excessive bending stress on the drilling string.
,~T TMM A R Zr f1F TNVFNTTlIN
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The present invention is directed at a drilling direction control device. The
invention is also directed at methods of drilling utilizing a drilling
direction control device and
to methods for orienting a drilling system such as a rotary drilling system.
In an apparatus form of the invention the invention is comprised of a device
which can be connected with a drilling string and which permits drilling to be
conducted in a
multitude of directions which deviate from the longitudinal axis of the
drilling string, thus
providing steering capability during drilling and control over the path of the
resulting wellbore.
Preferably, the device permits the amount of rate of change of the drilling
direction to be
infinitely variable between zero percent and 100 percent of the capacity of
the device.
The device is comprised of a drilling shaft which is connectable with the
drilling
string and which is deflectable by bending to alter the direction of its
longitudinal axis relative
to the longitudinal axis of the drilling string and thus alter the direction
of a drilling bit attached
thereto. Preferably, the orientation of the deflection of the drilling shaft
may be altered to alter
the orientation of the drilling bit with respect to both the toolface and the
magnitude of the
deflection of the drilling bit or the bit tilt.
Preferably, the drilling shaft is deflectable between two radial supports.
Preferably a length of the drilling shaft which is to be deflected is
contained within a housing,
which housing also encloses the radial supports.
The device is especially suited for use as part of a steerable rotary drilling
system
in which the drilling string and the drilling shaft are both rotated.
In one apparatus aspect of the invention, the invention is comprised of a
drilling
direction control device comprising:
(a) a rotatable drilling shaft;
(b) a housing for rotatably supporting a length of the drilling shaft for
rotation
therein; and
(c) a drilling shaft deflection assembly contained within the housing and
axially
located between a first suppot~t location and a second support location, for
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bending the drilling shaft between the first support location and the second
support location, wherein the deflection assembly is comprised of:
(i) an outer ring which is rotatably supported on a circular imier
peripheral surface of the housing and which has a circular inner
peripheral surface that is eccentric with respect to the housing;
and
(ii) an itmer ring which is rotatably suppot~ted on the circular inner
peripheral surface of the outer ring and which has a circular inner
peripheral surface which engages the drilling shaft and which is
eccentric with respect to the circular inner peripheral surface of
the outer ring.
1 ~ In other apparatus aspects of the invention, the invention is comprised of
improvements in features of drilling direction control devices generally.
These improvements
may be used in conjunction with the drilling direction control device
described above or may be
used in conjunction with other drilling direction control devices.
The first support location and the second support location may be comprised of
any stntcture which facilitates the bending of the drilling shaft therebetween
and which permits
rotation of the drilling shaft. Preferably the device is further comprised of
a first radial bearing
located at the first support location and a second radial bearing located at
the second support
location. Preferably the first radial bearing is comprised of a distal radial
bearing, the first
support location is comprised of a distal radial bearing location, the second
radial bearing is
comprised of a proximal radial bearing, and the second bearing location is
comprised of a
proximal radial bearing location.
The distal radial bearing may be comprised of any bearing, bushing or similar
device which is capable of radially and rotatably supporting the drilling
shaft while transmitting
the effects of deflection of the drilling shaft past the distal radial
bearing. For example, the
distal radial bearing may allow for radial displacement of the drilling shaft.
Preferably,
however, the distal radial bearing is comprised of a fulcrum bearing which
facilitates pivoting
of the drilling shaft at the distal radial bearing location.
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The proximal radial bearing may be comprised of any bearing, bushing or
similar
device which is capable of radially and rotatably supporting the drilling
shaft. Preferably, the
proximal radial bearing does not significantly transmit the effects of
deflection of the drilling
shaft past the proximal radial bearing so that the effects of deflection of
the drilling shaft are
confined to that portion of the device which is toward the distal end of the
device fr0111 the
proximal radial bearing. In the preferred embodiment, the proximal radial
bearing is comprised
of a cantilever bearing which restrains pivoting of the drilling shaft at the
proximal radial
bearing location.
The device preferably is further comprised of a distal seal at a distal end of
the
hOl.lSttlg and a proximal seal at a proximal eIld of the housing, both of
which are positioned
radially between the housing and the drilling shaft to isolate and protect the
radial bearings and
the deflection assembly fi-otn debris. The seals are preferably positioned
axially so that the
deflection assembly is axially located between the distal and proximal ends of
the housing, the
distal radial bearing location is axially located between the distal end of
the housing and the
deflection assembly, and the proximal radial bearing location is axially
located between the
proximal end of the holl5tllg and the deflection assembly.
The seals may be comprised of any type of seal tvhich is capable of
withstanding
relative movement between the housing and the drilling shaft as well as the h
tgh temperatures
and pressures that are likely to be encountered during drilling. Preferably
the seals are rotary
seals to accommodate rotation of the drilling shaft relative to the housing.
In the preferred
embodiment, the seals are comprised of rotary seals which also accommodate
lateral movement
of the drilling shaft, are comprised of an internal wiper seal and an external
barrier seal, and are
lubricated with filtered lubricating fluid from within the housing.
The interior of the housing preferably defines a fluid chamber between the
distal
end and the proximal end, which fluid chamber is preferably filled with a
lubricating fluid. The
device preferably is further comprised of a pressure compensation system for
balancing the
pressure of the lubricating fluid contained in the fluid chamber with the
ambient pressure
outside of the housing.
The pressure compensation system tray be comprised of any system which will
achieve the desired balance of pressures, such as any system which allows
communication
between the ambient pressure outside of the housing and the lubricating fluid
contained in the
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fluid chamber. In the preferred embodiment, the pressure compensation system
is comprised of
a pressure port on the housing.
The pressure compensation system is also preferably comprised of a
supplementary pressure source for exerting pressure on the lubricating fluid
so that the pressure
of the lubricating fluid is maintained higher than the ambient pressure. Any
mechanism which
provides this supplementary pressure source may be used in the invention,
which mechanism
may be actuated hydraulically, pneumatically, mechanically or in any other
manner.
In the preferred embodiment, the pressure compensation system includes the
supplementary pressure source and is comprised of a balancing piston assembly,
wherein the
balancing piston assembly is comprised of a piston chamber defined by the
interior of the
housing and a movable piston contained within the piston chamber which
separates the piston
chamber into a fluid chamber side and a balancing side, wherein the fluid
chamber side is
colmected with the fluid chamber, wherein the pressure port communicates with
the balancing
side of the piston chamber, and wherein the supplemental-y pressure source
acts on the
balancing side of the pIStOIl Challlber. In the prefer-ed eIllbOdlIllellt, the
supplementary pressure
source is comprised of a biasing device which exerts a supplementary pressure
on the piston,
and the biasing device is comprised of a spring WhlCh 1S Colltallled in the
balancing side of the
piston chamber.
The pressure compensation system is also preferably comprised of a lubricating
fluid regulating system which facilitates charging of the fluid chamber with
lubricating fluid
and which provides adjustment during operation of the device of the amount of
lubricating fluid
contained in the fluid chamber in response to increased temperatures and
pressures experienced
by the lubricating fluid.
The lubricating fluid regulating system is preferably comprised of a relief
valve
whlCh COIT1I11L1111CateS wlth the fluid chamber and which permits efflux of
lubricating fluid from
the fluid chamber when the difference between the pressure of the lubricating
fluid in the fluid
chamber and the ambient pressure outside of the fluid chamber exceeds a
predetermined relief
valve pressure. This predetermined relief valve pressure is preferably equal
to or slightly
greater than the supplementary pressure exel-ted by the supplementary pressure
source. In the
preferred embodiment, where the supplementary pressure source is a spring, the
predetermined
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relief valve pressure is set at slightly higher than the desired maximum
amount of
supplementary pressure to be exerted by the spring during operation of the
device.
The distal seal and the proximal seal are both preferably lubricated with
lubricating fluid from the fluid chamber. In order to reduce the risk of
damage to the seals due
to debris contained in the lubricating fluid, the seals are preferably each
comprised of an
internal wiper seal or internal isolation seal and a filtering mechanism for
filtering the
lubricating fluid from the fluid chamber before it encounters the seals so
that the seals are
isolated from the Il1a1tl VOILltl7e Of lLlbrlCatlIlg fluld contained within
the fluid chamber and are
lubricated with filtered lubricating fluid. Any type of filter capable of
isolating the seals from
debris having particles of the size likely to be encountered inside the fluid
chamber may be
used in the filtering mechanism.
The device is preferably further comprised of a device associated with the
housing for restraining rotation of the housing. The rotation restraining
device may be
comprised of any apparatus which is capable of providing a restraining or anti-
rotation function
between the housing and a borehole wall during operation of the drilling
direction control
device.
The rotation restraining device or anti-rotation may be comprised of a single
111eIl1beC exteLldlllg fr0111 the housing. Preferably, the rotation
restraining device is comprised of
a plurality of members arranged about a circumference of the housing, each of
which members
are capable of protruding radially from the housing and are capable of
engaging the borehole
wall to perform the restraining or anti-rotation function.
In one preferred embodiment of the invention, the rotation restraining device
is
comprised of at least one roller on the housing, the roller having an axis of
rotation
substantially perpendicular to a longitudinal axis of the housing and being
oriented such that it
is capable of r011111g about its axis of rotation in response to a force
exerted on the roller
substantially in the direction of the longitudinal axis of the housing.
Preferably the roller is comprised of a peripheral surface about its
circumference
and preferably the peripheral surface is comprised of an engagement surface
for engaging a
borehole wall. The engagement surface may be comprised of the peripheral
surface of the
roller being tapered.
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The roller may be positioned on the housing at a fixed radial position
extending
from the housing, but preferably the roller is capable of 1110Ve171el1t
beriveen a retracted position
and an extended position in which it extends from the housing. The rotation
restraining device
may be further comprised of a biasing device for biasing the roller toward the
extended
position, which biasing device may be comprised of any apparatus which can
perform the
biasing function. Preferably the biasing device is comprised of at least one
spring which acts
between the housing and the roller. Alternatively, the rotation restraining
device may be
comprised of an actuator for moving the roller between the retracted and
extended positions.
lU
Preferably the first preferred embodiment of rotation restraining device is
comprised of a plurality of rollers spaced about a circumference of the
housing. The plurality
of rollers may be spaced about the circumference of the housing in any
configuration. In the
preferred embodiment of rotation restraining device comprising rollers, the
rotation restraining
device is comprised of three rotation restraining carnage assemblies spaced
substantially evenly
about the circumference of the housing, wherein each rotation restraining
carnage assembly is
comprised of three sets of rollers spaced axially along the housing, and
wherein each set of
rollers is comprised of four coaxial rollers spaced side to side.
In a second prefewed embodiment of the Illvellt1011, the rotation restraining
device is comprised of at least one piston on the housing. The piston may be a
fixed member
which does not move radially relative to the housing. Preferably, the piston
is capable of
movement between a retracted position and an extended position in which it
extends radially
from the housing, in which case the rotation restraining device is preferably
further comprised
of an actuator device for moving the piston behveen the retracted and extended
positions. The
actuator device may be comprised of any apparatus which is capable of moving
the piston
radially relative to the housing. In the preferred embodiment, the actuator
device is comprised
of a hydraulic pump. Alternatively, the rotation restraining device may be
comprised of a
biasing device for biasing the piston toward the extended position.
Preferably the second preferred embodiment of rotation restraining device is
comprised of a plurality of pistons spaced about a circumference of the
housing. The plurality
of pistons may be spaced about the circumference of the housing in any
configuration. In the
prefen-ed embodiment of rotation restraining device comprising pistons, the
rotation restraining
3~ device is comprised of tlu-ee rotation restraining can-iage assemblies
spaced substantially evenly
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about the circumference of the housnlg, wherein each rotation restraining
carriage assembly 1S
comprised of a plurality of pistons spaced axially along the housing.
The device is preferably further comprised of a distal thrust bearing
contained
within the housing for rotatably supporting the drilling shaft axially at a
distal thrust bearing
location and a proximal t111-ust bearing contained within the housing for
rotatably supporting the
drilling shaft axially at a proximal thrust bearing location. The thrust
bearings may be
comprised of any bearing, bushing or similar device which is capable of
axially and rotatably
supporting the drilling shaft.
The tlu-ust bearings may be located at any axial positions on the device in
order
to distribute axial loads exerted on the device between the drilling shaft and
the housing.
Preferably the thrust bearings also isolate the deflection assembly from axial
loads exerted
through the device. As a result, the distal thrust bearing location is
preferably located axially
1 S between the distal end of the housing and the deflection assembly, and the
proximal thrust
bearing location is preferably located axially between the proximal end of the
housing and the
deflection assembly. This configuration permits the thrust bearings to be
lubricated with
lubClCat111g fhlld fl'Olll the fluid chamber.
Preferably the proximal thrust bearing location is located axially beriveen
the
proximal end of the housing and the proximal radial bearing location. This
configuration
simplifies the design of the proximal thrust bearing location, particularly
where the proximal
radial bearing is comprised of a cantilever bearing and the proximal thrust
bearing is thus
isolated from the effects of deflection of the drilling shaft. The proximal
thrust bearing may
also be located at the proximal radial bearing location so that the proximal
radial bearing is
comprised of the proximal thmst bearing.
Preferably, the distal thnlst bearing is comprised of the fulcrum bearing so
that
the distal thrust bearing location is at the distal radial bearing location.
The fulcrum bearing
may in such circumstances be comprised of any configuration of bearings,
bushings or similar
devices which enables the fulcnlm bearing to function as both a radial bearing
and a thrust
bearing while continuing to permit the effects of deflection of the drilling
shaft to be
transmitted past the fulcra lm bearing.
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In the preferred embodiment, the fulcnun bearing is preferably comprised of a
fulcrum bearing assembly, wherein the fulcrum bearing assembly is preferably
comprised of at
least one row of spherical thrust bearings positioned at first axial position,
at least one row of
spherical tln-ust bearings positioned at a second axial position and at least
one row of spherical
S radial bearings positioned at a third axial position, wherein the third
axial position is located
between the first and second axial positions. Preferably the spherical thrust
bearings and the
spherical radial bearings are arranged substantially about a common center of
rotation.
The thrust bearings are preferably maintained in a preloaded condition in
order to
minimize the likelihood of relative axial movement during operation of the
device between the
drilling shaft and the housing. The radial bearings may also be preloaded to
minimize the
likelihood of relative radial movement during operation of the device between
the drilling shaft
and the housing. In the preferred embodiment, the proximal thrust bearing and
the fulcrum
bearing are both preloaded.
1S
The thrust bearings may be preloaded in any mamer. Preferably the apparatus
for preloading the bearings provides for adjustment of the amount of
preloading to
accommodate different operating conditions for the device.
In the preferred embodiment, the tlumst bearings are preloaded. As a result,
in
the prefewed embodiment the device is further comprised of a distal thrust
bearing preload
assembly and a proximal thrust bearing preload assembly. In the preferred
embodiment, each
thrust bearing preload assembly is comprised of a thrust bearing shoulder and
a thrust bearing
collar, bet<veen which a thrust bearing is axially maintained. The thrust
bearing collar is axially
2S adjustable to preload the thrust bearing and to adjust the amount of
preloading. In the preferred
embodiment, the thrust bearing collar is threaded onto the housing and is
axially adjustable by
rotation relative to the housing.
In order to reduce the likelihood of a thrust bearing collar becoming loosened
by
axial movement during operation of the device, the device is preferably
further comprised of a
distal thrust bearing retainer for retaining the distal thrust bearing in
position without increasing
the preloading on the distal tlu-ust bearing, and is further comprised of a
proximal thrust bearing
retainer for retaining the proximal thrust bearing in position without
increasing the preloading
on the proximal thmst bearing.
JS
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CA 02569070 2006-12-15
The tlu-ust bearing retainers may be comprised of any apparatus which
functions
to maintain the desired axial position of the thrust bearing collars without
applying an
additional compressive load to the thrust bearings. Preferably this result is
achieved by
retaining the thrust bearing collars against axial movement with a compressive
force which is
not applied to the thrust bearings.
In the preferred embodiment, each thrust bearing retainer is comprised of a
locking ring slidably mounted on the thrust bearing collar to a position in
which it abuts the
housing and a locking ring collar which can be tightened against the locking
ring to hold the
locking ring in position between the housing and the locking ring collar.
Alternatively, the
locking ring maybe adapted to abut some component of the device other than the
housing as
long as the force exerted by the tightening of the locking ring collar is not
borne by the thrust
bearing.
In the preferred embodiment, the tlu-ust bearing collar is threaded for
adjustment
by rotation and the locking ring is mounted on the thrust bearing collar such
that the locking
ring does not rotate relative to the thrust bearing collar. Preferably, the
apparatus for mounting
the locking ring on the tlu-ust bearing collar is comprised of a key on one
and an axially
oriented slot on the other of the locking ring and the thrust bearing collar.
Airy other suitable
mounting apparatus may, however, be used.
The locking ring may be held abutted against the housing or other component of
the device by the frictional forces resulting from the tightening of the
locking ring collar. In the
preferred embodiment, the locking ring is comprised of a housing abutment
surface, the
housing is comprised of a complementary locking ring abutment surface, and
engagement of
the housing abutment surface and the locking ring abutment surface prevents
rotation of the
locking ring relative to the housing. In the preferred embodiment, the
abutment surfaces are
comprised of complementary teeth.
In operation of the tlttltst bearing preload assembly and the thrust bearing
retainer, the anlOLltlt of thrust bearing preload is established by rotating
the tlu-ust bearing collar
to establish a suitable axial load representing the desired amount of
preloading on the thrust
bearing. The locking ring is then slid over the thrust bearing collar until it
abuts the housing
and the COlllple111entary abutment surfaces are engaged and the locking ring
collar is then
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CA 02569070 2006-12-15
tightened against the locking ring to hold the locking ring in position
between the housing and
the locking ring collar at a desired torque load.
The deflection assembly may be actuated by any mechanism or mechanisms
which are capable of independently rotating the outer ring and the iluzer
ring. The actuating
mechanism may be independently powered, but in the prefel-red embodiment the
actuating
mechanism utilizes rotation of the drilling shaft as a source of power to
effect rotation of the
outer ring and the ilmer ring.
Preferably, the deflection assembly is further comprised of an outer ring
drive
mechanism for rotating the outer ring using rotation of the drilling shaft and
a substantially
identical imler ring drive mechanism for rotating the inner ring using
rotation of the drilling
shaft. Preferably, the inner and outer rings are rotated in a direction
opposite to the direction of
rotation of the drilling string and thus opposite to a direction of rotation
of slippage of the non-
rotating portion of the device (20), being the housing (46).
In the preferred embodiment, each drive mechanism is comprised of a clutch for
selectively engaging and disengaging the drilling shaft fi-om the ring,
wherein the clutch is
comprised of a pair of clutch plates which are separated by a clutch gap when
the clutch is
disengaged. Preferably, each clutch may also function as a brake for the inner
and outer rings
when the clutch plates are disengaged.
Each clutch is further comprised of a clutch adjustment mechanism for
adjusting
the clutch gap. Any mechanism facilitating the adjustment of the clutch gap
may be used for
the clutch adjustment mechanism.
Preferably, each clutch adjustment Illecha111S111 IS COnlprlSed of a clutch
adjustment member associated with one of the pair of clutch plates such that
movement of the
clutch adjustment member will result in col-responding movement of the clutch
plate, a first
guide for guiding the clutch adjustment member for movement in a first
direction, and a
movable key associated with the clutch adjustment member, the key comprising a
second guide
for urging the clutch adjustment member in a second direction, which second
direction has a
component parallel to the first guide and has a component perpendicular to the
first guide.
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CA 02569070 2006-12-15
The first guide may be comprised of any structure which is capable of guiding
the clutch adjustment member for movement in the first direction. Similarly,
the second guide
may be comprised of any stl-ucture which is capable of urging the clutch
adjustment member in
the second direction.
S
The clutch adjustment member, the key and the clutch plate are preferably
associated with each other such that the key effects movement of the clutch
adjustment member
which in turn effects movement of the clutch plate to increase or decrease the
clutch gap. The
clutch adjustment member may therefore be rigidly attached to or integrally
formed with one of
the key or the clutch plate, but should be capable of some movement relative
to the other of the
key and the clutch plate.
The function of the first guide is to enable the key and the clutch plate to
move
relative to each other without imparting a significant force to the clutch
plate tending to rotate
the clutch plate. In other words, the movement of the key in the second
direction is converted
through the apparatus of the key, the clutch adjustment member, the first
guide and the clutch
plate into movement of the clutch plate in a direction necessary to increase
or decrease the
clutch gap.
In the preferred embodiment, the first guide is comprised of a first slot
which
extends circumferentially in the clutch plate and thus perpendicular to a
direction of movement
of the clutch plate necessary to increase or decrease the clutch gap, the
clutch adjustment
member is fixed to the key, and the clutch adjustment member engages the first
slot.
Preferably, the second guide is comprised of a surface which urges the key to
move in the
second direction in response to a force applied to the key. In the preferred
embodiment, the
surface is comprised in part of a key ramp surface which is oriented in the
second direction.
In the preferred embodiment, the clutch adjustment mechanism is further
comprised of a clutch adjustment control mechanism for controlling the
movement of the key.
This clutch adjustment control mechanism may be comprised of any apparatus,
but in the
preferred embodiment is comprised of an adjustment screw which is connected to
the key and
which can be rotated inside a threaded bore to finely control the movement of
the key.
In the prefeled eIllbod1111eI1t, the clutch adjustment illeChaIllSln 1S
further
comprised of a clutch adjustment locking mechanism for fixing the position of
the key so that
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CA 02569070 2006-12-15
the clutch gap can be maintained at a desired setting. This clutch adjustment
locking
mechanism may be comprised of any apparatus, but in the preferred embodiment
is comprised
of one or more set screws associated with the clutch adjustment member which
can be tightened
to fix the position of the key once the desired clutch gap setting is
achieved.
S
Preferably the clutch adjustment control mechanism controls movement of the
key in a direction that is substantially perpendicular to the longitudinal
axis of the device. As a
result, the second guide preferably converts movement of the key in a
direction substantially
perpendicular to the longitudinal axis of the device to movement of the key in
the second
direction.
In the preferred embodiment, the key is positioned in a cavity defined by the
ring
drive mechanism. In addition, in the preferred embodiment the key is comprised
of a key ramp
surface oriented in the second direction and the cavity defines a
complementary cavity ramp
surface, so that movement of the key by the clutch adjustment control
mechanism in a direction
that is substantially perpendicular to the longitudinal axis of the device
results in the key
moving along the cavity ramp surface in the second direction, which in turn
causes the clutch
adjustment member to move in the second direction.
The component of movement of the key along the cavity ramp surface which is
parallel to the first slot results in the clutch adjustment member moving in
the first slot without
imparting a significant rotational force to the clutch plate. The component of
movement of the
key along the cavity ramp surface which is perpendicular to the first slot
results in an increase
or decrease in the clutch gap by engagement of the clutch adjustment member
with the clutch
plate.
Alternatively, the clutch adjustment member may be fixed to the clutch plate
so
that the clutch adjustment member does not move relative to the clutch plate.
In this second
embodiment of clutch adjustment mechanism, the first guide is preferably
comprised of a first
slot which is oriented in a direction that is parallel to a direction of
movement necessary to
increase or decrease the clutch gap and is positioned between the key and the
clutch plate so
that the clutch adjustment member moves in the first guide. The second guide
in this
embodiment is preferably comprised of a second slot in the key which crosses
the first slot so
that the clutch adjustment member simultaneously engages both the first slot
and the second
slot.
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CA 02569070 2006-12-15
In the second embodiment of clutch adjustment mechanism, the key may not
include the key ramp surface, in which case the second slot is preferably
oriented in the second
direction. Alternatively, the key may include the key ramp surface, in which
case the second
slot is preferably oriented in the second direction.
The device is preferably incorporated into a drilling string by connecting the
drilling shaft with the drilling string. In order that rotation of the
drilling string will result in
rotation of the drilling shaft, the device is further comprised of a drive
connection for
cotmecting the drilling shaft with the drilling string.
The drive comiection may be comprised of any apparatus which is capable of
transmitting torque from the drilling string to the drilling shaft.
Preferably, the drive
connection is sufficiently tight between the drilling string and the drilling
shaft so that the drive
comlection is substantially "backlash-free".
In the prefen -ed embodiment, the drive comlection is comprised of a tolerance
assimilation sleeve which is interspersed between the drilling shaft and the
drilling string. In
the preferred enlbOdlnlellt, the drive connection is further comprised of a
first drive profile on
the drilling shaft and a complementary second drive profile on the drilling
string and the
tolerance assimilation sleeve is positioned between the first drive profile
and the second drive
profile in order to reduce the tolerance between the first drive profile and
the second drive
profile.
?5 The first and second drive profiles may be comprised of any complementary
configurations which facilitate the transmission of torque between the
drilling string and the
drilling shaft. In the preferred embodiment, the first and second drive
profiles are comprised of
octagonal profiles and the tolerance assimilation sleeve includes compatible
octagonal profiles.
The tolerance assimilation sleeve thus absorbs or assimilates some of the
tolerance between the
octagonal profile on the drilling shaft and the complementary octagonal
profile on the drilling
string in order to make the transmission of torque between the drilling string
and the drilling
shaft 1110re SIllOOth alld substantially "backlash-free".
In the prefen-ed embodiment, the effectiveness of the tolerance assimilation
sleeve is further enhanced by the sleeve being comprised of a material having
a thermal
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CA 02569070 2006-12-15
expansion rate higher than the thel-lnal expansion rate of the drilling
string, so that the tolerance
assimilation sleeve will absorb or assimilate more tolerance between the
drilling shaft and the
drilling string as the device is exposed to increasing temperatures during its
operation. In the
preferred embodiment, the tolerance assimilation sleeve is comprised of a
beryllium copper
alloy.
The deflection assembly is preferably actuated to orient the outer ring and
the
inner ring relative to a reference orientation so that the device may be used
to provide
directional control during drilling operations.
Preferably, the deflection assembly is actuated with reference to the
orientation
of the housing, which is preferably restrained from rotating during operation
of the device by
the rotation restraining device. As a result, the device is preferably further
comprised of a
housing orientation sensor apparatus associated with the housing for sensing
the orientation of
the housing.
The housing orientation sensor apparatus preferably senses the orientation of
the
housing in three dimensions in space and may be comprised of any apparatus
which is capable
of providing this sensing function and the desired accuracy in sensing.
Preferably the housing
orientation sensor apparatus is comprised of one or more magnetometers,
accelerometers or a
combination of both types of sensing apparatus.
The housing orientation sensing apparatus is preferably located as close as
possible to the distal end of the housing so that the sensed orientation of
the housing will be as
close as possible to the distal end of the borehole during operation of the
device. In the
preferred embodiment, the housing orientation sensor apparatus is contained in
an at-bit-
inclination (ABI) insert which is located inside the housing axially between
the distal radial
bearing and the deflection assembly.
The device is also preferably filrther comprised of a deflection assembly
orientation sensor apparatus associated with the deflection assembly for
sensing the orientation
of the deflection assembly.
The deflection assembly orientation sensor apparatus may provide for sensing
of
3~ the orientation of the outer ring and the ilmer ring in three dimensions in
space, in which case
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CA 02569070 2006-12-15
the deflection assembly orientation sensor apparatus may be comprised of an
apparatus similar
to that of the housing orientation sensor apparatus and may even eliminate the
need for the
housing orientation sensor apparatus.
Preferably, however the deflection assembly orientation sensor apparatus
senses
the orientation of both the outer ring and the imer ring of the deflection
assembly relative to the
llollSlllg and may be comprised of any apparatus which is capable of providing
this sensing
function and the desired accuracy in sensing. The deflection assembly
orientation sensor
apparatus may be comprised of one sensor which senses the resultant
orientation of the inner
peripheral surface of the imer ring relative to the housing.
In the preferred embodiment, the deflection assembly orientation sensor
apparatus is comprised of separate sensor apparatus for sensing the
orientation of each of the
outer ring and the inner ring relative to the housing. In the preferred
embodiment, these sensor
apparatus are comprised of a plurality of magnets associated with each of the
drive mechanisms
which rotate with components of the drive mechanism. The magnetic fields
generated by these
magnets are then sensed by a stationary counter device associated with a non-
rotating
component of the drive mechanism to sense how far the rings rotate from a
reference or home
position.
The deflection assembly orientation sensor apparatus may be further comprised
of one or more high speed position sensors associated with each drive
mechanism, for sensing
the rotation which is actually transmitted from the drilling shaft tluough the
clutch to the drive
mechanism. The high speed position sensors may be associated with an rpm
sensor which in
turn is associated with the drilling shaft for sensing the rotation of the
drilling shaft. A
comparison of the rotation sensed by the high speed position sensors and the
rotation sensed by
the ipm sensor may be used to determine slippage through the clutch and detect
possible
malfunctioning of the clutch.
The deflection assembly is preferably actuated with reference to the
orientation
of both the hOLls111g and the deflection assembly, since the housing
orientation sensor apparatus
preferably senses the orientation of the housing in space while the deflection
assembly
orientation sensor apparatus preferably senses the orientation of the outer
ring and the inner
ring relative to the housing.
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CA 02569070 2006-12-15
The deflection assembly may be actuated by manipulating the deflection
assembly using any device or apparatus which is capable of rotating the outer
and inner rings,
Preferably, however the device is fin-ther comprised of a controller for
controlling the actuation
of the deflection assembly. Preferably, the controller is operatively
comlected with both the
housing orientation sensor apparatus and the deflection assembly orientation
sensor apparatus
so that the deflection assembly may be actuated by the controller with
reference to the
orientation of both the housing and the deflection assembly.
The controller may be positioned at any location at which it is capable of
performing the controlling function. The controller may therefore be
positioned between the
proximal and distal ends of the housing, along the drilling string, or may
even be located
outside of the borehole. In the preferred embodiment, the controller is
located in an electronics
insert which is positioned axially between the proximal radial bearing and the
deflection
assembly.
One of the features of the preferred embodiment of the invention is that the
device is preferably compatible with drilling string communication systems
which facilitate the
transmission of data from or to dowW ole locations. Such communication systems
often
include sensors for sensing parameters such as the orientation of the drilling
string. Preferably
the device is capable of processing data received from sensors associated with
such drilling
string communication systems in order to control the actuation of the
deflection assembly.
Preferably the device is operated by connecting a drilling string
communication
system with the device so that a drilling string orientation sensor apparatus
is operatively
connected with the device and the deflection assembly may be actuated with
reference to the
orientation of the drilling string. By considering the orientation of the
drilling string, the
orientation of the housing and the orientation of the deflection assembly
relative to the housing,
and by establishing a relationship linking the three orientations, the
deflection assembly may be
actuated to reflect a desired orientation of the drilling string once data
pertaining to the desired
orientation of the drilling string has been processed by the device to provide
instructions for
actuation of the deflection assembly.
This relationship linking the tl-u-ee orientations may be established in any
manner. In the preferred embodiment the relationship is established by
providing reference
positions for each of the housing orientation sensor apparatus, the deflection
assembly
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CA 02569070 2006-12-15
orientation sensor apparatus and the drilling string orientation sensor
apparatus which can be
related to one another.
The deflection assembly may be actuated indirectly by the device converting
data
pertaining to the orientation of the drilling Strlllg or some other parameter
or the deflection
assembly may be actuated directly by the device receiving instructions
specifically pertaining to
the actuation of the deflection assembly. Preferably, however the controller
is connectable with
a drilling string orientation sensor apparatus so that the deflection assembly
may be actuated
indirectly by the device converting data pertaining to the orientation of the
drilling string.
This configuration simplifies the operation of the device, since an operator
of the
device need only establish a desired orientation of the drilling string
through communication
with the drilling string communication system. The drilling string
communication system can
then provide instructions to the device in the form of data pertaining to the
desired orientation
of the drilling string which the device will then process having regard to the
orientation of the
housing and the orientation of the deflection assembly relative to the housing
in order to actuate
the deflection assembly to reflect the desired orientation of the drilling
string. Preferably the
data is processed by the controller of the device.
The device may be further comprised of a device memory for storing data
downloaded to control the operation of the device, data generated by the
housing orientation
sensor apparatus, the deflection assembly orientation sensor apparatus, the
drilling string
orientation sensor apparatus, or data obtained from some other source such as,
for example an
operator of the device. The device memory is preferably associated with the
controller, but
may be positioned anywhere between the proximal and distal ends of the
housing, along the
drilling string, or may even be located outside of the borehole. During
operation of the device,
data may be retrieved from the device memory as needed in order to control the
operation of the
device, including the actuation of the deflection assembly.
In the prefen -ed embodiment the housing orientation sensor apparatus, the
deflection assembly orientation sensor apparatus, the drilling string
orientation sensor apparatus
and the controller all transmit electrical signals between various components
of the device and
the drilling string, lllCludlllg the deflection assembly, the controller and
the drilling stung
Co1111nU111Cat1011 SyStelll.
-23-
CA 02569070 2006-12-15
In order to transmit electrical signals from the housing to the drilling
shaft, and
thus the drilling string communication system, it is necessary in the
preferred embodiment to
transmit these signals between two components which are rotating relative to
each other, which
may render conventional electrical circuits impractical for this purpose.
These signals may be transmitted between the components by any direct or
indirect coupling or communication method or any mechanism, structure or
device for directly
or indirectly COLlpllllg the COIIIpOnentS WhlCh are rotating relative to each
other. For instance,
the signals may be transmitted by a slip ring or a gamma-at-bit communication
toroid coupler.
However, in the preferred embodiment, the signals are transmitted by an
electromagnetic
coupling device.
As a result, in the preferred embodiment, the device is further comprised of
an
electromagnetic coupling device associated with the housing and the drilling
shaft for
electrically connecting the drilling shaft and the housing.
This electromagnetic coupling device is preferably comprised of a housing
conductor positioned on the housing and a drilling shaft conductor positioned
on the drilling
shaft, wherein the housing conductor and the drilling shaft conductor are
positioned sufficiently
close to each other so that electrical signals may be induced between them.
The conductors
may be single wires or coils and may either be wrapped or not wrapped around
magnetically
permeable cores.
The invention is also comprised of methods for orienting a drilling system,
which methods are particularly suited for orienting a rotary drilling system.
The methods may
be performed manually or on a fillly automated or semi-automated basis.
The methods may be performed manually by having an operator provide
instructions to the drilling direction control device. The methods may be
performed fully
automatically or semi-automatically by having a drilling string communication
system provide
instructions to the drilling direction control device.
As described above with respect to the apparatus embodiments, one of the
features of the preferred e111bOdi111el1t of the 111Ve11t1011 1S that the
invention may be used in
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CA 02569070 2006-12-15
conjunction with drilling string communication systems and is capable of
interfacing with such
systems.
For example, the invention may be used in conjunction with a measurement-
S while-drilling (MWD) apparatus which may be incorporated into a drilling
string for insertion
in a borehole as part of an MWD system. In an MWD system, sensors associated
with the
MWD apparatus provide data to the MWD apparatus for communication up the
drilling string
to an operator of the drilling system. These sensors typically provide
directional information
about the borehole being drilled by sensing the orientation of the drilling
string so that the
operator can monitor the orientation of the drilling string in response to
data received from the
MWD apparatus and adjust the orientation of the drilling string in response to
such data. An
MWD system also typically enables the communication of data from the operator
of the system
down the borehole to the MWD apparatus.
1 S Preferably, the drilling direction control device of the invention is
capable of
communicating with the MWD system or other drilling string communication
system so that
data concerning the orientation of the drilling string can be received by the
device. Preferably,
the drilling direction control device is also capable of processing data
received from the drilling
string communication system pertaining to the orientation of the drilling
string in order to
generate instructions for actuation of the deflection assembly.
In other words, preferably the drilling direction control device communicates
with the drilling string communication system and not directly with the
operator of the drilling
system. In addition, preferably the drilling direction control device is
capable of interfacing
with the drilling string communication system such that it can process data
received from the
communication system.
This will allow the operator of the drilling system to be concerned primarily
with
the orientation of the drilling string during drilling operations, since the
drilling direction
control device will interface with the drilling Slrlllg COLn1nt1111Cat1o11
System aIld adjust the
deflection assembly with reference to the orientation of the drilling string.
This is made
possible by establishing a relationship amongst the orientation of the
drilling string, the
Orlelltatloll Of the hOtlslllg and the orientation of the deflection assembly,
thus simplifying
drilling operations.
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CA 02569070 2006-12-15
Establishing a communication link between the drilling direction control
device
and the drilling string CO111111uI11Cat1011 Sy5ter11 facilitates the operation
of the drilling direction
control device on a fully automated or semi-automated basis with reference to
the orientation of
the drilling string. The device may also be operated using a combination of
manual, fully
automated and semi-automated methods, and may be assisted by expert systems
and artificial
intelligence (AI) to address actual drilling conditions that are different
from the expected
drilling conditions.
Operation of the drilling direction control device on a fully automated basis
involves preprogramming the device with a desired actuation of the device or
with a series of
desired actuations of the device. The device may then be operated in
conjunction with the
drilling string communication system to effect drilling for a preprogrammed
duration at one
desired orientation of the drilling string, followed by drilling for a
preprogrammed duration at a
second desired orientation of the drilling string, and so on. The device may
be programmed
indirectly with data pertaining to the desired orientation of the drilling
string or programmed
directly with specific instructions pertaining to the actuation of the device.
Preferably the
programming is performed indirectly and the device processes the data to
generate instructions
for actuating the device.
Operation of the drilling direction control device on a semi-automated basis
involves establishing a desired actuation of the device before the
commencement of drilling
operations and actuating the deflection assembly to deflect the drilling shaft
to reflect the
desired actuation. This desired actuation is then maintained until a new
desired actuation is
established and will typically require temporary cessation of drilling to
permit the deflection
assembly to be actuated to reflect the new desired actuation of the device.
The desired
actuation of the device may be established indirectly by providing the device
with data
pertaining to the desired orientation of the drilling string or may be
established directly by
providing the device with specific instructions pertaining to actuation of the
device. Preferably
the desired actuation of the device is given indirectly and the device
processes the data to
generate instructions for actuating the device.
Operation of the drilling direction control device may also involve
maintaining
the deflection of the drilling shaft during drilling operations so that the
deflection of the drilling
shaft continues to reflect the desired actuation of the device. In the
preferred embodiment, the
maintaining step may be necessary where some rotation of the housing is
experienced during
-26-
CA 02569070 2006-12-15
drilling operations and may involve adjusting the actuation of the deflection
assembly to
account for rotational displacement of the housing, since the deflection
assembly in the
preferred e111bOd1Illeilt is actuated relative to the housing. The actuation
of the deflection
assembly may also require adjusting to account for undesired slippage of the
clutch or
clutch/brake comprising the drive mechanisms of the ilmer and outer rings of
the deflection
assembly.
The maintaining step may be performed manually by an operator providing
instlllctions to the device to adjust the deflection of the drilling shaft.
Preferably, however, the
maintaining step is automated so that the drilling string communication system
provides
instructions to the device to adjust the deflection of the drilling shaft.
These instructions may
be given indirectly by providing the device with data pertaining to the
orientation of the drilling
string or may be given directly by providing the device with specific
instructions for actuating
the device to adjust the deflection of the drilling shaft. Preferably the
instructions are given
indirectly and the device processes the data to generate instructions for
actuating the device.
As a result, in one method aspect of the invention, the invention is comprised
of
a method for orienting a rotary drilling system, the rotary drilling system
being comprised of a
rotatable drilling string, a drilling string communication system and a
drilling direction control
device, the drilling direction control device comprising a deflectable
drilling shaft connected
with the drilling string, the method comprising the following steps:
(a) orienting the drilling string at a desired orientation;
(b) sensing the desired orientation of the drilling string with the drilling
string
communication system;
(c) CO111111u111Catlllg the desired orientation of the drilling string to the
drilling
direction control device; and
(d) actuating the drilling direction control device to deflect the drilling
shaft to
reflect the desired orientation.
Preferably the drilling direction control device is actuated to reflect the
desired
orientation by actuating the device to account for the relative positions of
the drilling string and
-2 7-
CA 02569070 2006-12-15
the actuating apparatus. In a preferred embodiment, the drilling direction
control device is
further comprised of a housing and a deflection assembly, and the drilling
direction control
device is actuated to reflect the desired orientation of the device by
accounting for the relative
positions of the drilling string, the housing and the deflection assembly.
The drilling direction control device may be actuated in any manner and may be
powered separately from the rotary drilling system. In the preferred
embodiment, the drilling
direction control device is actuated by rotation of the drilling string and
the actuating step is
comprised of rotating the drilling string.
The orienting step lnay be comprised of communicating the desired orientation
of the drilling string directly from the surface of the wellbore to the
drilling direction control
device either with or without manipulating the drilling string. Preferably,
however, the
orienting step is comprised of comparing a current orientation of the drilling
string with the
1 S desired orientation of the drilling string and rotating the drilling
string to eliminate any
discrepancy between the current orientation and the desired orientation. Once
the desired
orientation of the drilling string is achieved by manipulation of the drilling
string, the desired
orientation may then be COI11n1L1111Cated to the drilling direction control
device either directly
from the surface of the wellbore or from a drilling string orientation sensor
located somewhere
on the drilling string.
The method may also be comprised of the further step of periodically .
communicating the current orientation of the drilling string to the drilling
direction control
device. Preferably, the current orientation of the drilling string is
periodically communicated to
the drilling direction control device after a predetermined delay.
The step of communicating the desired orientation of the drilling string to
the
drilling direction control device may be comprised of communicating the
desired orientation of
the drilling string from the drilling string COI11111L1111Cat1011 System to
the drilling direction
control device and the step of periodically communicating the current
orientation of the drilling
string to the drilling direction control device may be comprised of
periodically communicating
the cunent orientation of the drilling string from the drilling string
communication system to
the drilling direction control device.
-28-
CA 02569070 2006-12-15
The actuating step may be comprised of waiting for a period of time equal to
or
greater than the predetermined delay once the drilling string is oriented at
the desired
orientation so that the desired orientation of the drilling string is
communicated to the drilling
direction control device and rotating the drilling string to actuate the
drilling direction control
device to reflect the desired orientation of the drilling string.
The drilling direction control device may be further comprised of a device
IllelllOry, in which case the method may be further comprised of the step of
storing the current
orientation of the drilling string in the device memory when it is
communicated to the drilling
direction control device.
Where the drilling direction control device is further comprised of a device
memory, the actuating step may be further comprised of the steps of retrieving
from the device
memory the desired orientation of the drilling string and rotating the
drilling string to actuate
the drilling direction control device to reflect the desired orientation of
the drilling string.
The method may be further comprised of the step of maintaining the deflection
of the drilling shaft to reflect the desired orientation of the drilling shaft
during operation of the
rotary drilling system. The orientation maintaining step may be comprised of
the steps of
communicating the current orientation of the drilling string from the drilling
string
communication system to the drilling direction control device and actuating
the drilling
direction control device to reflect the desired orientation of the drilling
string and the current
orientation of the drilling shaft.
In a second method aspect of the invention, the invention is comprised of a
method for orienting a rotary drilling system, the rotary drilling system
being comprised of a
rotatable drilling string, a drilling string COI111T1uI11Cat10n SyStenl arid a
drilling direction control
device, the drilling direction control device comprising a deflectable
drilling shaft connected
with the drilling string, the method comprising the following steps:
(a) CO111n1ll111Catlllg a desired orientation of the drilling string to the
drilling direction
control device; and
(b) actuating the drilling direction control device to deflect the drilling
shaft to
reflect the desired orientation.
-29-
CA 02569070 2006-12-15
Preferably the drilling direction control device is actuated to reflect the
desired
orientation by actuating the device to aCCOllllt for the relative positions of
the drilling string and
the actuating apparatus. In a prefel-red embodiment, the drilling direction
control device is
further comprised of a housing and a deflection assembly, and the drilling
direction control
device is actuated to reflect the desired orientation of the device by
accounting for the relative
positions of the drilling string, the housing and the deflection assembly.
The drilling direction control device may be actuated in any manner and may be
powered separately from the rotary drilling system. In the preferred
embodiment, the drilling
direction control device is actuated by rotation of the drilling string and
the actuating step is
comprised of rotating the drilling string.
The method may also be comprised of the further step of periodically
communicating the current orientation of the drilling string to the drilling
direction control
device. Preferably, the current orientation of the drilling string is
periodically communicated to
the drilling direction control device after a predetermined delay.
The step of C0121n1u111Ca.tlllg the desired orientation of the drilling string
to the
drilling direction control device may be comprised of communicating the
desired orientation of
the drilling stl-ing from the drilling string communication system to the
drilling direction
control device and the step of periodic;~lly communicating the current
orientation of the drilling
string to the drilling direction control device may be comprised of
periodically communicating
the current orientation of the drilling string from the drilling string
communication system to
the drilling direction control device.
The actuating step may be comprised of waiting for a period of time less than
the
predetermined delay so that the current: orientation of the drilling string is
not communicated to
the drilling direction control device and rotating the drilling string to
actuate the drilling
direction control device to reflect the d~°sired orientation of the
drilling string.
The drilling direction control device may be further comprised of a device
memory, in which case the method may be fiu-ther comprised of the step of
storing the desired
orientation of the drilling string in the device memory when it is
communicated to the drilling
direction control device.
-30-
CA 02569070 2006-12-15
Where the drilling direction control device is further comprised of a device
memory, the actuating step may be further comprised of the steps of retrieving
from the device
memory the desired orientation of the drilling string and rotating the
drilling string to actuate
the drilling direction control device to reflect the desired orientation of
the drilling string.
The method may be fiu-ther comprised of the step of maintaining the deflection
of the drilling shaft to reflect the desired orientation of the drilling shaft
during operation of the
rotary drilling system. The orientation maintaining step may be comprised of
the steps of
communicating the cunent orientation of the drilling string from the drilling
string
communication system to the drilling direction control device and actuating
the drilling
direction control device to reflect the desired orientation of the drilling
string and the current
orientation of the drilling shaft.
In a third method aspect of the invention, the invention is comprised of a
method
for orienting a rotary drilling system, the rotary drilling system being
comprised of a rotatable
drilling string, a drilling string COnllnunlCatloil SySteln, aIld a drilling
direction control device,
the drilling direction control device comprising a deflectable drilling shaft
connected with the
drilling string, the method comprising the following steps:
(a) detern~ining a desired orientation of the rotary drilling system;
(b) communicating the desired orientation of the rotary drilling system from
the
drilling string communication system to the drilling direction control device;
and
(c) actuating the drilling direction control device to deflect the drilling
shaft to
reflect the desired orientation of the rotary drilling system.
The drilling direction control device may be further comprised of a device
memory, in which case the Illethod may be further comprised of the step of
storing the desired
orientation of the rotary drilling system in the device memory when it is
communicated to the
drilling direction control device.
Where the drilling direction control device is further comprised of a device
memory, the actuating step may be further comprised of the steps of retrieving
from the device
-3 I-
CA 02569070 2006-12-15
memory the desired orientation of th~° rotary drilling system and
rotating the drilling string to
actuate the drilling direction control device to reflect the desired
orientation of the rotary
drilling system.
The method may be further comprised of the step of maintaining the desired
orientation of the rotary drilling system during operation of the rotary
drilling system. The
orientation maintaining step may be comprised of the steps of communicating
the cul-rent
orientation of the rotary drilling SyStE;lll from the drilling string
CO111muL11Cat1011 System to the
drilling direction control device and actuating the drilling direction control
device to reflect the
desired orientation of the rotary drilling system and the current ol-ientation
of the drilling shaft.
In any of the method aspects of the invention, the drilling direction control
device may be further comprised of a housing for rotatably supporting the
drilling shaft and the
Orlelltatlon 111 a1ntallllllg step may be comprised of adjusting the
deflection of the drilling shaft
to account for rotation of the housing during drilling operations.
In addition, the drilling direction control device is preferably equipped to
respond to basic default lllStrlICtlOnS COIICemlllg the magnitude of
deflection of the drilling
shaft. For example, the device is preferably equipped to provide for a zero
deflection mode
where the inner and outer rings are oriented opposite to each other to provide
for no deflection
of the drilling shaft and a full deflection mode where the deflection of the
drilling shaft is a
maximum predetermined amount, which predetermined amount may be equal to or
less than the
maximum deflection permitted by the deflection assembly. The device may also
be equipped
to respond to a plurality of default instructions such as zero deflection,
full deflection and
numerous magnitudes of deflection in 'between.
Where the device is in zero deflection mode, drilling is perfol-lned without
altering the drilling direction. In other words, drilling is permitted to
proceed in a substantially
straight direction. The zero deflection mode also permits the device to be nm
into and out of
the wellbore.
BRIEF DESCRIPTION OF DRAWINGS
Embodiments of the invention will now be described with reference to the
accompanying drawings, in which:
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CA 02569070 2006-12-15
Figure 1 is a pictorial siide view of a preferred embodiment of a drilling
direction
control device comprising a rotary drilling system;
Figure 2(a) is a pictorial side view, having a cut-away portion, of the
drilling
direction control device shown in Figure 1 contained within a wellbore and
comprising a
drilling shaft, wherein the drilling shat is in an undeflected condition;
Figure 2(b) is a schematic cross-sectional view of a deflection assembly of
the
drilling direction control device shown in Figure 2(a) in an undeflected
condition;
Figure 3(a) is a pictorial side view, having a cut-away portion, of the
drilling
direction control device shown in Figure 1 contained within a wellbore,
wherein the drilling
shaft is in a deflected condition;
Figure 3(b) is a schematic cross-sectional view of a deflection assembly of
the
drilling direction control device shown. in Figure 3(a) in a deflected
condition;
Figures 4(a) tluough 4(g) are longitudinal sectional views of the drilling
direction control device shown in Figures 2 and 3, wherein Figures 4(b)
through 4(g) are lower
continuations of Figures 4(a) through ~l(f) respectively;
Figure S is a more detailed schematic cross-sectional view of the deflection
assembly of the drilling direction control device shown in Figures 2(b) and
3(b);
Figure 6 is a pictorial view of a pouion of the deflection assembly of the
drilling
direction control device shown in Figure l;
Figure 7 is a pictorial side view of a preferred rotation restraining device
comprising the drilling direction control device shown in Figure 1;
Figure 8 is an exploded pictorial side view of the preferred rotation
restraining
device shown in Figure 7;
-33-
CA 02569070 2006-12-15
Figure 9 is a pictorial side view of an alternate rotation restraining device
comprising the drilling direction control device shown in Figure l; and
Figure 10 is an explod~°d pictorial side view of the alternate rotation
restraining
device shown in Figure 9.
DETAILED DESCRIPTION
The within invention is comprised of a drilling direction control device (20)
and
a method for using the device (20). 'l.'he device (20) permits directional
control over a drilling
bit (22) cormected with the device (20) during rotary drilling operations by
controlling the
orientation of the drilling bit (22). As a result, the direction of the
resulting wellbore may be
controlled. Specifically, in the preferred embodiment, the device (20) and
method of the within
invention maintain the desired orientation of the drilling bit (22) by
maintaining the desired
toolface of the drilling bit (22) and the desired bit tilt angle, while
preferably enhancing the
rotations per minute and rate of penetration.
The drllhllg dlreCt10I1 COlltr0l devlCe (20) is comprised of a rotatable
drilling
shaft (24) which is connectable or attachable to a rotary drilling string (25)
during the drilling
operation. More pauicularly, the drilling shaft (24) has a proximal end (26)
and a distal end
(2S). The proximal end (26) is drivingly connectable or attachable with the
rotary drilling
string (25) such that rotation of the drilling string (25) from the surface
results in a
corresponding rotation of the drilling shaft (24). The proximal end (26) of
the drilling shaft
(24) may be permanently or remova~bly attached, connected or otherwise affixed
with the
drilling string (25) in any mamer and by any structure, mechanism, device or
method
peucnitting the rotation of the drilling shaft (24) upon the rotation of the
drilling string (25).
Preferably, the device (20) is further comprised of a drive connection for
connecting the drilling shaft (24) with the drilling string (25). As
indicated, the drive
connection may be comprised of any structure, mechanism or device for
drivingly connecting
the drilling shaft (24) and the drillin;; string (25) so that rotation of the
drilling string (25)
results in a corresponding rotation of the drilling shaft (24). However,
preferably, the drive
connection is comprised of a tolerance assimilation sleeve (30). More
particularly, the
tolerance assimilation sleeve (30) is interspersed or positioned between the
proximal end (26)
of the drilling shaft (24) and the adjacent end of the drilling string (25).
-34-
CA 02569070 2006-12-15
Preferably, the drive connection is comprised of a first drive profile (32) on
or
defined by the drilling shaft (24), and particularly, on or defined by the
proximal end (26) of the
drilling shaft (24). The drive comlection is further comprised of a second
drive profile (34),
complementary to the first drive profile (32), on or defined by the adjacent
end of the drilling
string (25) to be drivingly connected with the drilling shaft (24) of the
device (20). The
tolerance assimilation sleeve (30) is positioned or interspersed between the
first drive profile
(32) and the second drive profile (34) in order to reduce the tolerance
between the first drive
profile (32) and the second drive profile (34) and provide a backlash free
drive. The first and
second drive profiles (32, 34) are thus sized and configured to be
complementary to and
compatible with the tolerance assimilation sleeve (30) therebetween.
In the preferred embodiment, the first drive profile (32) is defined by an
outer
surface (33) of the proximal end (26) of the drilling shaft (24). Further, the
second drive profile
(34) is defined by an inner surface (36) of the adjacent end of the drilling
string (25). Thus, the
tolerance assimilation sleeve (30) is positioned between the outer surface
(33) of the drilling
shaft (24) and the inner surface (36) of the drilling string (25). More
particularly, the tolerance
assimilation sleeve (30) has an outer surface (38) for engaging the inner
surface (36) of the
drilling string (25) and an inner surface (40) for engaging the outer surface
(33) of the drilling
shaft (24).
As indicated, the adjacent outer surface (38) of the sleeve (30) and inner
surface
(36) of the drilling string (25) and adjacent im~er surface (40) of the sleeve
(30) and outer
surface (33) of the drilling shaft (24) may have any shape or configuration
compatible with
providing a driving connection therebe;hveen and capable of reducing the
tolerance between the
first drive profile (32) and the complementary second drive profile (34).
However, in the
preferred embodiment, the tolerance; assimilation sleeve (30) has octagonal
internal and
external profiles. In other words, both the imer and outer surfaces (40, 38)
of the sleeve (30)
are octagonal on cross-section.
In addition, preferably, the drilling shaft (24), the drilling string (25) and
the
tolerance assimilation sleeve (30) therebetween are configured such that
torque or radial loads
only are transmitted between the drilling shaft (24) and the drilling string
(25). In other words,
preferably, no significant axial forces or loads are transmitted therebetween
by the tolerance
assimilation sleeve (30). Thus, although the tolerance assimilation sleeve
(30) may be tied or
-35-
CA 02569070 2006-12-15
anchored with one of the drilling shaft (24) and the drilling string (25), it
is preferably not tied
or anchored with both the drilling shaft (24) and the drilling string (25). In
the preferred
embodiment, the tolerance assimilation sleeve (30) is tied or anchored with
neither the drilling
shaft (24) nor the drilling string (25).
Further, the tolerance assimilation sleeve (30) may reduce the tolerance
between
the first and second drive profiles (32, 34) in any mariner and by any
mechanism of action. For
instance, preferably, the tolerance assimilation sleeve is comprised of a
material having a
thernial expansion rate higher than the. thermal expansion rate of the
drilling string (25). In the
prefen-ed embodiment, the drilling shaft (24) has the highest thernzal
expansion rate and the
drilling string (25) has the lowest thermal expansion rate. The thermal
expansion rate of the
tolerance assimilation sleeve (30) is preferably between that of the drilling
shaft (24) and the
drilling string (25).
Any material providing for this differential rate of thermal expansion and
having
a relatively high strength compatible with the drilling operation may be used.
However, in the
preferred embodiment, the tolerance assimilation sleeve (30) is a beryllium
copper sleeve.
Similarly, the distal end (28) of the drilling shaft (24) is drivingly
connectable or
attachable with the rotary drilling bit (22) such that rotation of the
drilling shaft (24) by the
drilling string (25) results in a corresponding rotation of the drilling bit
(22). The distal end
(28) of the drilling shaft (24) may be permanently or removably attached,
connected or
otherwise affixed with the drilling bit (22) in any manner and by any
structure, mechanism,
device or method permitting the rotation of the drilling bit (22) upon the
rotation of the drilling
shaft (24). In the preferred embodirnent, a threaded com~ection is provided
therebetween.
More particularly, an firmer surface (42) of the distal end (28) of the
drilling shaft (24) is
threadably connected and drivingly engaged with an adjacent outer surface (44)
of the drilling
bit (22).
The device (20) of the within invention provides for the controlled deflection
of
the drilling shaft (24) resulting in a band or curvature of the drilling shaft
(24), as described
further below, in order to provide th.e desired deflection of the attached
drilling bit (22).
Preferably, the orientation of the deflection of the drilling shaft (24) may
be altered to alter the
orientation of the drilling bit (22) or toolface, while the magnitude of the
deflection of the
-36-
CA 02569070 2006-12-15
drilling shaft (24) may be altered to vary the magnitude of the deflection of
the drilling bit (22)
or the bit tilt.
The drilling shaft (24) may be comprised of one or more elements or portions
comiected, attached or otherwise affixed together in any suitable mariner
providing a unitary
drilling shaft (24) bet'veen the proximal and distal ends (26, 28).
Preferably, any connections
provided behveen the elements or portions of the drilling shaft (24) are
relatively rigid such that
the drilling shaft (24) does not include any flexible joints or articulations
therein. In the
preferred embodiment, the drilling shaft (24) is comprised of a single,
unitary or integral
element extending between the proximal and distal ends (26, 28). Further, the
drilling shaft
(24) is tubular or hollow to permit drilling fluid to flow therethrough in a
relatively unrestricted
or unimpeded mariner.
Finally, the drilling shaft (24) may be comprised of any material suitable for
and
compatible with rotary drilling. In the preferred embodiment, the drilling
shaft (24) is
comprised of high strength stainless steel.
Further, the device (20) is comprised of a housing (46) for rotatably
supporting a
length of the drilling shaft (24) for rotation therein upon rotation of the
attached drilling string
(25). The housing (46) may support, and extend along, any Length of the
drilling shaft (24).
However, preferably, the housing (46) supports substantially the entire length
of the drilling
shaft (24) and extends substantially between the proximal and distal ends (26,
28) of the drilling
shaft (24).
In the preferred embodiment, the housing (46) has a proximal end (48) adjacent
or in proximity to the proximal end (26) of the drilling shaft (24).
Specifically, the proximal
end (26) of the drilling shaft (24) extends from the proximal end (48) of the
housing (46) for
comlection with the drilling string (25). However, in addition, a portion of
the adjacent drilling
string (25) may extend within the proximal end (48) of the housing (46).
Similarly, in the
preferred e117bOd1IIlellt, the housing (4(i) has a distal end (50) adjacent or
in proximity to the
distal end (28) of the drilling shaft (24). Specifically, the distal end (28)
of the drilling shaft
(24) extends fr0111 the distal end (50) of the housing (46) for connection
with the drilling bit
(22).
-3 7-
CA 02569070 2006-12-15
The hOLlslIlg (46) may be comprised of one or more tubular or hollow elements,
sections or components permanently or removably comiected, attached or
otherwise affixed
together to provide a unitary or integral housing (46) pel-mitting the
drilling shaft (24) to extend
therethrough. However, in the prefen-ed embodiment, the housing (46) is
comprised of three
sections or portions connected together. Specifically, starting at the
proximal end (48) and
moving towards the distal end (50) of the housing (46), the housing (46) is
comprised of a
proximal housing section (52), a central housing section (54) and a distal
housing section (56).
More particularly, the proximal end (48) of the housing (46) is defined by a
proximal end (58) of the proximal housing section (52). A distal end (60) of
the proximal
housing section (52) is connected with a proximal end (62) of the central
housing section (54).
Similarly, a distal end (64) of the central housing section (54) is connected
with a proximal end
(66) of the distal housing section (56). The distal end (50) of the housing
(46) is defined by a
distal end (68) of the distal housing section (56).
As indicated, the distal end (60) of the proximal housing section (52) and the
proximal end (62) of the central housing section (54), as well as the distal
end (64) of the
central housing section (54) and the proximal end (66) of the distal housing
section (56), may
each be permanently or removably attached, connected or otherwise affixed
together in any
manner and by any structure, mechanism, device or method permitting the
formation of a
unitary housing (46).
However, in the prefewed embodiment, both of the connections are provided by
a threaded cormection between the adjacent ends. More particularly, the
proximal housing
section (52) has an inner surface (70) and an outer surface (72). Similarly,
the central housing
section (54) has an inner surface (74) and an outer surface (76) and the
distal housing section
(56) has an inner surface (78) and an outer surface (80). The outer surface
(72) of the proximal
housing section (52) at its distal end (60) is threadably comlected with the
inner surface (74) of
the central housing section (54) at its proximal end (62). Similarly, the
outer surface (76) of the
central housing section (54) at its distal end (64) is threadably comlected
with the iltner surface
(78) of the distal housing section (56) at its proximal end (66).
The device (20) is Further comprised of at least one distal radial bearing
(82) and
at least one proximal radial bearing (84). Each of the radial bearings (82,
84) is contained
within the hOLislllg (46) for rotatably supporting the drilling shaft (24)
radially at the location of
-38-
CA 02569070 2006-12-15
that particular radial bearing (82, 84). The radial bearings (82, 84) may be
positioned at any
locations along the length of the drilling shaft (24) permitting the bearings
(82, 84) to rotatably
radially support the drilling shaft (24) within the housing (46). In addition,
the radial bearings
(82, 84) are positioned between the drilling shaft (24) and the housing (46).
In addition, one or more further radial bearings may be contained within the
housing (46) to assist in supporting the drilling shaft (24). Where such
further radial bearings
are provided, these further radial bearings are located distally or downhole
to the distal radial
bearing (82) and proximally or uphole of the proximal radial bearing (84). In
other words,
preferably, the further radial bearings are not located between the distal and
proximal radial
bearings (82, 84).
Preferably, at least one distal radial bearing (82) is contained within the
housing
(46) for rotatably supporting the drilling shaft (24) radially at a distal
radial bearing location
(86) defined thereby. In the preferred embodiment, the distal radial bearing
(82) is contained
wlthlll the distal housing section (56), positioned between the inner surface
(78) of the distal
housing section (56) and the drilling shaft (24), for rotatably supporting the
drilling shaft (24)
radially at the distal radial bearing location (86) defined thereby.
Although the distal radial bearing (82) may be comprised of any radial bearing
able to rotatably support the drilling shaft (24) within the housing (46) at
the distal radial
bearing location (86), the distal radial bearing (82) is preferably comprised
of a fulcrum bearing
(88), also referred to as a focal bearing, as described in greater detail
below. The fulcrum
bearing (88) facilitates the pivoting of the drilling shaft (24) at the distal
radial bearing location
(86) upon the controlled deflection of the drilling shaft (24) by the device
(20) to produce a
bending or curvature of the drilling shaft (24) in order to orient or direct
the drilling bit (22).
Preferably, the device (20) is further comprised of a near bit stabilizer
(89),
which in the prefen -ed embodiment is located adjacent to the distal end (50)
of the housing (46)
and coincides with the distal radial bearing location (86). The near bit
stabilizer (89) may be
comprised of any type of stabilizer.
Further, preferably, at least one proximal radial bearing (84) is contained
within
the housing (46) for rotatably supporting the drilling shaft (24) radially at
a proximal radial
bearing location (90) deftned thereby. In the preferred embodiment, the
proximal radial bearing
-3 9-
CA 02569070 2006-12-15
(84) is contained wthln the central housing section (54), positioned between
the inner surface
(74) of the central housing section (54) and the dI-~IIIIlg shaft (24), for
rotatably supporting the
drilling shaft (24) radially at the proximal radial bearing location (90)
defined thereby.
Although the proximal radial bearing (84) may be comprised of any radial
bearing able to rotatably radially support the drilling shaft (24) within the
housing (46) at the
proximal radial bearing location (90), the proximal radial bearing (84) is
preferably comprised
of a cantilever bearing.
Upon the controlled deflection of the drilling shaft (24) by the device (20),
as
described further below, the curvature or bending of the drilling shaft (24)
is produced
downhole of the cantilever proximal radial bearing (84). In other words, the
controlled
deflection of the drilling shaft (24), and thus the cur<~ature of the drilling
shaft (24), occurs
between the proximal radial bearing location (90) and the distal radial
bearing location (86).
The cantilever nature of the proximal radial bearing (84) inhibits the bending
of the drilling
shaft (24) uphole or above the proximal radial bearing (84). The fulcrum
bearing comprising
the distal radial bearing (82) facilitates the pivoting of the drilling shaft
(24) and permits the
drilling bit (22) to tilt in any desired direction. Specifically, the drilling
bit (22) is permitted to
tilt in the opposite direction of the bending direction.
Further, the device (20) is comprised of a drilling shaft deflection assembly
(92)
contained within the housing (46) for bending the drilling shaft (24) therein.
The deflection
assembly (92) may be located axially at any location or position beriveen the
distal end (SO) and
the proximal end (48) of the housing (46). However, the distal radial bearing
location (86) is
preferably axially located between the distal end (50) of the housing (46) and
the deflection
assembly (92), while the proximal radial bearing location (90) is preferably
axially located
between the proximal end (48) of the housing (46) and the deflection assembly
(92). In other
words, the chilling shaft deflection assembly (92) is preferably located
axially along the length
of the drilling shaft (24) at a location or position between the distal radial
bearing location (86)
and the proximal radial bearing location (90). As described previously, in the
preferred
embodiment, the deflection assembly (92) is provided for bending the drilling
shaft (24)
between the distal radial bearing location (86) and the proximal radial
bearing location (90).
In the preferred embodiment, the deflection assembly (92) is contained within
the distal housing section (56) between the imer surface (78) of the distal
housing section (56)
-40-
CA 02569070 2006-12-15
and the drilling string (24). The distal radial bearing location (86) is
axially located between
the distal end (68) of the distal housing section (56) and the deflection
assembly (92), while the
proximal radial bearing location (90) is axially located between the
deflection assembly (92)
and the proximal end (48) of the housing (46).
In addition to the radial bearings (82, 84) for rotatably supporting the
drilling
shaft (24) radially, the device (20) further preferably includes one or more
thrust bearings for
rotatably supporting the drilling shaft (24) axially. Preferably, the device
(20) is comprised of
at least one distal thrust bearing (94) and at least one proximal thrust
bearing (96). As
indicated, each of the thrust bearings (94, 96) is contained within the
housing (46) for rotatably
supporting the drilling shaft (24) axially at the location of that particular
thrust bearing (94, 96).
The thrust bearings (94, 96) may be positioned at any locations along the
length of the drilling
shaft (24) permitting the bearings (94, 96) to rotatably support the drilling
shaft (24) axially
within the housing (46). In addition, the thrust bearings (94, 96) are
positioned between the
drilling shaft (24) and the housing (46).
However, preferably, at least one distal thrust bearing (94) is contained
within
the housing (4G) for rotatably supporting the drilling shaft (24) axially at a
distal thrust bearing
location (98) defined thereby. The distal thrust bearing location (98) is
preferably located
axially between the distal end (50) of the housing (46) and the deflection
assembly (92). In the
preferred embodiment, the distal thrust bearing (94) is contained within the
distal housing
section (56), positioned between the inner surface (78) of the distal housing
section (56) and the
drilling shaft (24), for rotatably supporting the drilling shaft (24) axially.
Thus, the distal thrust
bearing location (98) is located axially between the distal end (68) of the
distal housing section
(56) and the deflection assembly (92).
Although the distal thrust bearing (94) may be comprised of any thrust bearing
able to rotatably and axially support the drilling shaft (24) within the
housing (46) at the distal
thrust bearing location (98), the distal thrust bearing (94) is preferably
comprised of the fulcrum
bearing (88) described above. Thus, the distal thrust bearing location (98) is
at the distal radial
bearing location (86).
Fuc-ther, preferably, at least one proximal thrust bearing (96) is contained
within
the hollSlllg (46) for rotatably supporting the drilling shaft (24) axially at
a proximal thrust
3~ bearing location (100) defined thereby. The proximal thrust bearing
location (100) is
-41-
CA 02569070 2006-12-15
preferably located axially between the proximal end (48) of the housing (46)
and the deflection
assembly (92). In addition, more preferably, the proximal thrust bearing
location (100) is located
axially between the proximal end (48) of the housing (46) and the proximal
radial bearing location
(90).
Preferably, the proximal thrust bearing (96) is contained within the proximal
housing section (52), positioned between the inner surface (70) of the
proximal housing section
(52) and the drilling shaft (24), for rotatably supporting the drilling shaft
(24) axially. More
particularly, In the preferred embodiment where the drilling string (25)
extends into the proximal
end (48) of the housing (46), the proximal thrust bearing (96 ) is located
between the inner surface
(70) of the proximal housing section (52) and an outer surface of the drilling
string (25). The
proximal thrust bearing (96) may be comprised of any thrust bearing.
As a result of the thrust bearings (94, 96), most of the weight on the
drilling bit (22)
may be transferred into and through the housing (46) as compared to through
the drilling shaft (24)
of the device (20). Thus, the drilling shaft (24) may be permitted to be
slimmer and more
controllable. As well, most of the drilling weight bypasses the drilling shaft
(24) substantially
between its proximal and distal ends (48, 50) and thus bypasses the other
components of the device
(20) including the deflection assembly (92). More particularly, weight applied
on the drilling bit
(22) through the drill string (25) is transferred, at least in part, from the
drilling string (25) to the
proximal end (48) of the housing (46) by the proximal thrust bearing (96) at
the proximal thrust
bearing location (100). The weight is further transferred, at least in part,
from the distal end (50)
of the housing (46) to the drilling shaft (24), and thus the attached drilling
bit (22), by the fulcrum
bearing (88) at the distal thrust bearing location (98).
The fulcrum bearing (88) may be comprised of any combination or configuration
of
radial and thrust bearings able to radially and axially support the rotating
drilling shaft (24) within
the housing (46). However, preferably the fulcrum bearing (88) is comprised of
a fulcrum bearing
assembly. The fulcrum bearing assembly is comprised of at least one row of
spherical roller distal
thrust bearings (94) positioned at a first axial position (102) and at least
one row of spherical roller
distal thrust bearings (94) positioned at a second axial position ( 104). In
addition, the fulcrum
bearing assembly is comprised of at least one row of spherical distal radial
bearings (82)
-42-
CA 02569070 2006-12-15
positioned at a third axial position (106), wherein the third axial position
(106) is located between
the first axial position (102) and the second axial position (104). The
spherical roller distal thrust
bearings (94) and the spherical distal radial bearings (82) are arranged
substantially about a
common center of rotation. As a result, as described above, the fulcrum
bearing assembly allows
the drilling bit (22) to tilt in any desired direction and to rotate
relatively freely while transferring
most of the drilling bit (22) weight into the housing (46).
Each of the distal and proximal thrust bearings (94, 96) is preferably
preloaded at
the desired distal and proximal thrust bearing locations (98, 100)
respectively. Any mechanism,
structure, device or method capable of preloading the thrust bearings (94, 96)
the desired amount
may be utilized. Further, preferably, the mechanism, structure, device or
method used substantially
maintains the desired preloading during the drilling operation. In addition,
although preferred, the
same mechanism, structure, device or method need not be used for preloading
both thrust bearings
(94, 96).
Referring first to the distal thrust bearing (94), the distal thrust bearing
(94) is
axially maintained within the housing (46) at the distal thrust bearing
location (98) between a distal
thrust bearing shoulder (108) and a distal thrust bearing collar (110). Thus,
in the preferred
embodiment, the fulcrum bearing assembly (88) comprising the spherical roller
distal thrust
bearings (94) are axially maintained in position at the first and second axial
positions (102, 104)
between the distal thrust bearing shoulder (108) and the distal thrust bearing
collar (110). More
particularly, the distal thrust bearing shoulder (108) abuts, directly or
indirectly, against the
uppermost or uphole end of the fulcrum bearing assembly (88) comprising the
spherical roller
distal thrust bearings (94), while the distal thrust bearing collar (110)
abuts, directly or indirectly,
against the lowermost or downhole end of the of the fulcrum bearing assembly
(88).
Although any structure or component contained within the housing (46) adjacent
the
fulcrum bearing assembly uphole may provide or define the distal thrust
bearing shoulder (108),
the distal thrust bearing shoulder (108) is preferably defined by the inner
surface of the housing
(46). Thus, in the preferred embodiment, the distal thrust bearing shoulder
(108) is defined by the
inner surface (78) of the distal housing section (56) adjacent or in proximity
to the distal end (50)
of the housing (46).
-43-
CA 02569070 2006-12-15
The distal thrust bearing collar (110) is contained within the housing (46)
and
located about the drilling string (24) for abutment against the lowermost or
downhole end of the of
the fulcrum bearing assembly (88). Further, the distal thrust bearing collar
(110) is axially
adjustable relative to the distal thrust bearing shoulder (108) in order to
preload the distal thrust
bearings (94) located therebetween. In the preferred embodiment, given that
the distal thrust
bearings (94) are spherical, any radial loads tend to separate the bearings
(94), and thus, tend to
separate the fulcrum bearing (88). As a result, a sufficient preloading force
is applied to the distal
thrust bearings (94) such that the radial loads encountered by the thrust
bearings (94) will not
compromise the thrust bearings (94) within the fulcrum bearing (88).
Further, to facilitate the preloading, one or more springs or washers,
preferably
Belleville washers ( 111 ) are preferably located at, adjacent or in proximity
to the opposing ends of
the fulcrum bearing assembly (88) such that the Belleville washers (111) are
also axially
1 S maintained between the distal thrust bearing shoulder ( 108) and the
distal thrust bearing collar
( 110). Preloading of the distal thrust bearings (94) results in compression
of the Belleville washers
(111). In other words, in order to preload the bearings (94), the distal
thrust bearing collar (110) is
axially adjustable relative to the distal thrust bearing shoulder (108) in
order to preload the distal
thrust bearings (94) located therebetween by compressing the Belleville
washers (111).
The distal thrust bearing collar (110) may be adjusted axially in any manner
and by
any mechanism, structure or device able to axially adjust the distal thrust
bearing collar (110)
relative to the distal thrust bearing shoulder ( 108). However, preferably,
the distal thrust bearing
collar (110) is threaded for adjustment by rotation. More particularly, in the
preferred
embodiment, the distal thrust bearing collar (110) has a proximal end (114)
for abutting against the
adjacent fulcrum bearing assembly (88) and a distal end (116) extending from
and beyond the
distal end (68) of the distal housing section (56). An outer surface (118) of
the distal thrust bearing
collar ( 110) at its proximal end ( 114) is threaded for connection with a
complementary threaded
inner surface (78) of the distal housing section (56) at its distal end (68).
As a result of the
threaded connection, rotation of the distal thrust bearing collar (110)
axially adjusts the collar
(110) either towards or away from the distal thrust bearing shoulder (108) to
increase or decrease
the preloading respectively on the distal thrust bearings (94).
-44-
CA 02569070 2006-12-15
Further, the device (20) preferably provides for the retention of the distal
thrust
bearing or bearings (94) at the desired position without causing an increase
in the preloading
thereon. Any structure, device, mechanism or method able to retain the distal
thrust bearing (94)
in position without increasing the preloading thereon may be utilized.
However, preferably, the
device (20) is further comprised of a distal thrust bearing retainer (112) for
retaining the spherical
distal thrust bearings (94) comprising the fulcrum bearing assembly (88) in
position without
increasing the preloading on the spherical distal thrust bearings (94).
-44a-
CA 02569070 2006-12-15
In the preferred embodiment, the distal thrust bearing retainer (112) is
comprised
of a locking ring (120) and a locking ring collar (122). The locking ring
(I20) is slidably
lllOl111ted on the distal thrust bearing collar (110), about the outer surface
(118) of the collar
(110). Accordingly, once the distal thrust bearing collar (110) is axially
adjusted to preload the
bearing (94), the locking ring ( 120) may be selectively moved longitudinally
along the outer
surface (118) of the collar (110) to a position abutting the distal end (50)
of the housing (46).
Once the locking ring (120) is moved into abutment with the housing (46), the
locking ring collar ( 122) can be tightened against the locking ring ( 120) to
hold the locking ring
( 120) in position between the housing (46) and the locking ring collar (
122). The locking ring
(120) acts upon the distal thrust bearing collar (110) to inhibit the rotation
of the distal thrust
bearing collar (110) away from the distal thrust bearing shoulder (108) and
thus maintain the
preloading.
Preferably, the locking ring collar (122) is mounted about the drilling string
(24)
adjacent the distal end (50) of the housing (46) such that the locking ring
(120) is located or
positioned between the distal end (50) of the housing (46) and a proximal end
(124) of the
locking ring collar (122). Further, the locking ring collar (122) is axially
adjustable relative to
the housing (46) such that the locking ring (120) may be held therebetween
upon tightening of
the locking ring collar ( 122).
The locking ring collar (122) may be adjusted axially in any manner and by any
mechanism, structure or device able to axially adjust the locking ring collar
(122) relative to the
housing (46). However, preferably, the locking ring collar (122) is threaded
for adjustment by
rotation. More particularly, in the preferred embodiment, the outer surface
(118) of the distal
tlu-ust bearing collar (110) at its distal end (116) is threaded for
cormection with a
complementary threaded inner surface (126) of the locking ring collar (122) at
its proximal end
(124). As a result of the threaded connection, rotation of the locking ring
collar (122) axially
adjusts the locking ring collar (122) either towards or away from the distal
end (50) of the
housing (46) to tighten or release the locking ring (120) located
therebetween. In the preferred
embodiment, the locking ring collar (122) is tightened to between about 8000
to 10,000 ft lbs.
The tightening of the IOCkIIlg ring collar (122) holds the locking ring (120)
in position without
increasing the preloading on the distal thrust bearings (94).
-45-
CA 02569070 2006-12-15
When the locking ring collar (122) is tightened against the locking ring
(120), the
locking ring (120) acts upon the distal tlu-ust bearing collar (110) to
inhibit the rotation of the
distal tlu-ust bearing collar ( 110) away from the distal tlu-ust bearing
shoulder ( 108) and thus to
maintain the preloading. In order to enhance or facilitate the action of the
distal thrust bearing
retainer (112), the locking ring (120) preferably does not rotate, or is
inhibited from rotating,
relative to the distal thrust bearing collar (110). This relative rotation may
be prevented or
iWibited in any mariner and by any structure, device or mechanism capable of
preventing or
iWibiting the undesired relative rotation between the locking ring (120) and
the distal thrust
bearing collar (110). However, preferably, the locking ring (120) is mounted
on the distal
theist bearing collar ( 110) such that the locking ring ( 120) does not
rotate, or is inhibited from
rotating, relative to the distal thrust bearing collar ( 110).
The locking ring (120) may be mounted on the distal thrust bearing collar
(110)
in any manner and by any structure, device or mechanism capable of preventing
or inhibiting
the undesired relative rotation behveen the locking ring (120) and the distal
thrust bearing collar
(110). For instance, in the preferred embodiment, at least one key and slot
configuration is
utilized. Specifically, a key ( 123) extends between a slot or groove defined
by each of the
adjacent surfaces of the distal thrust bearing collar (110) and the distal
locking ring (120).
In addition, in order to fuather enhance or facilitate the action of the
distal thrust
bearing retainer (112), the locking ring (120) preferably does not rotate, or
is inhibited from
rotating, relative to the housing (46). This relative rotation may be
prevented or inhibited in
any mariner and by any stmcture, device or mechanism capable of preventing or
inhibiting the
undesired relative rotation between the locking ring ( 120) and the housing
(46). However,
preferably, the configurations of the adjacent abutting surfaces of the
locking ring (120) and the
housing (46) are complementary such that the locking ring (120) does not
rotate, or is inhibited
from rotating, relative to the housing (46).
In the prefen-ed embodiment, the locking ring is further comprised of a
housing
abutment surface (128). In addition, the housing (46), and in particular the
distal end (6$) of
the distal housing section (56), is further comprised of a locking ring
abutment surface (130).
The locking ring abutment surface (130) is complementary to the housing
abutment surface
(128) such that the engagement of the housing abutment surface (128) and the
locking ring
abutment surface ( 130) prevents or inhibits the rotation of the locking ring
( 120) relative to the
housing (46). Although any complementary surface configurations may be used,
the locking
-46-
CA 02569070 2006-12-15
ring abutment surface (130) and the housing abutment surface (128) each
preferably define a
plurality of complementary interlocking teeth.
Next, referring to the proximal thrust bearing (96), the proximal tlu-ust
bearing
(96) is axially maintained within the housing (46) and preloaded in a mariner
similar to that of
the distal thrust bearing (94) and by similar components or structure as
described above for the
distal thrust bearing (94).
The proximal thrust bearing or bearings (96) are axially maintained within the
housing (46) at the proximal thrust bearing location ( 100) bet<veen a
proximal thrust bearing
shoulder ( 132) and a proximal thrust bearing collar ( 134). More
particularly, the proximal
tlu-ust bearing shoulder ( 132) abuts, directly or indirectly, against the
lowermost or downhole
end of the proximal thrust bearing (96), while the proximal thrust bearing
collar (134) abuts,
directly or indirectly, against the uppermost or uphole end of the proximal
thrust bearing (96).
Although any stmcture or component contained within the housing (46) adjacent
the proximal tlu-ust bearing (96) uphole may provide or define the proximal
thrust bearing
shoulder (132), the proximal thrust bearing shoulder (132) is preferably
defined by the inner
surface of the hOllSlllg (46). Thus, in the preferred embodiment, the proximal
tlu-ust bearing
shoulder (132) is defined by the iru~er surface (70) of the proximal housing
section (52)
adjacent or in proximity to the proximal end (48) of the housing (46).
The proximal thrust bearing collar (134) is contained within the housing (46)
and
located about the drilling string (24) for abutment against the uppermost or
uphole end of the
proximal thrust bearing (96). Further, the proximal tlmlst bearing collar
(134) is axially
adjustable relative to the proximal thrust bearing shoulder (132) in order to
preload the
proximal thrust bearing or bearings (96) located therebetween. In the
preferred embodiment, in
contrast with the distal thrust bearings (94), the proximal thrust bearings
(96) are not spherical.
Thus, radial loads do not tend to separate the proximal thrust bearings (96)
and the bearing
preloading force applied to the proximal thrust bearings (96) may be
significantly less than that
applied to the distal thrust bearings (94).
To facilitate the preloading, one or more springs or washers, preferably a
washer
such as a wave washer, is preferably located or associated with the proximal
thrust bearings
(96) such that the washer is also axially maintained between the proximal
thnlst bearing
-47-
CA 02569070 2006-12-15
shoulder (132) and the proximal tlu-ust bearing collar (134), Preloading of
the proximal tlu-ust
bearings (96) results in compression of the washer. In other words, in order
to preload the
bearings (96), the proximal tlu-ust bearing collar (134) is axially adjustable
relative to the
proximal tlu-ust bearing shoulder ( 132) in order to preload the proximal
thrust bearings (96)
located therebetween by C'0111preSSlllg the ~Va511er.
The proximal thrust bearing collar (134) may be adjusted axially in any manner
and by any mechanism, structure or device able to axially adjust the proximal
thrust bearing
collar (134) relative to the proximal tlu~ust bearing shoulder (132). However,
preferably, the
proximal tlu~ust bearing collar (134) is threaded for adjustment by rotation.
More particularly,
in the prefewed embodiment, the proximal thrust bearing collar (134) has a
proximal end (138)
extending from and beyond the proximal end (58) of the proximal housing
section (52) arid a
distal end (140) for abutting against the adjacent proximal thrust bearing
(96). An outer surface
(142) of the proximal tluust bearing collar (134) at its distal end (140) is
threaded for
connection with a complementary threaded inner surface (70) of the proximal
housing section
(52) at its proximal end (58). As a result of the threaded connection,
rotation of the proximal
thrust bearing collar (134) axially adjusts the collar (134) either towards or
away from the
proximal thrust beating shoulder ( 132) to increase or decrease the preloading
respectively on
the proximal thrust bearing (96).
Further, the device (20) preferably similarly provides for the retention of
the
proximal thrust bearing or bearings (96) at the desired position without
causing an increase in
the preloading thereon. Any structure, device, mechanism or method able to
retain the
proximal thrust bearing (96) in position without increasing the preloading
thereon may be
utilized. However, preferably, the device (20) is further comprised of a
proximal thrust bearing
retainer (136) for retaining the proximal thrust bearing (96) in position
without increasing the
preloading on the proximal thrust bearing (96).
In the preferred embodiment, the proximal thrust bearing retainer (136) is
comprised of a locking ring (144) and a locking ring collar (146), The locking
ring (144) is
slidably mounted on the proximal tluztst bearing collar (134), about the outer
surface (142) of
the collar (134). Accordingly, once the proximal tlu-ust bearing collar (134)
is axially adjusted
to preload the bearing (96), the locking ring ( 144) may be selectively moved
longitudinally
along the outer surface (142) of the collar (134) to a position abutting the
proximal end (48) of
the housing (46).
-48-
CA 02569070 2006-12-15
Once the locking ring (144) is moved into abutment with the housing (46), the
locking ring collar (146) can be tightened against the locking ring (144) to
hold the locking ring
(144) in position betmeen the housing (46) and the locking ring collar (146).
The locking ring
S (144) acts upon the proximal thrust bearing collar (134) to inhibit the
rotation of the proximal
tlumst bearing collar (134) away from the proximal thrust bearing shoulder
(132) and thus
maintain the preloading.
Preferably, the locking ring collar (146) is mounted about the drilling string
(24)
adjacent the proximal end (48) of the housing (46) such that the locking ring
(144) is located or
positioned between the proximal end (48) of the housing (46) and a distal end
(148) of the
locking ring collar (146). Further, the locking ring collar (146) is axially
adjustable relative to
the housing (46) such that the locking ring (144) may be held therebetween
upon tightening of
the locking ring collar (146).
The locking ring collar (146) may be adjusted axially in any manner and by any
mechanism, structure or device able to axially adjust the locking ring collar
(146) relative to the
housing (46). However, preferably, the locking ring collar (146) is threaded
for adjustment by
rotation. More particularly, in the preferred embodiment, the outer surface
(142) of the
proximal thrust bearing collar (134) at its proximal end (13S) is threaded for
connection with a
complementary threaded firmer surface (1S0) of the locking ring collar (146)
at its distal end
(148). As a result of the threaded com~ection, rotation of the locking ring
collar (146) axially
adjusts the locking ring collar (146) either towards or away from the proximal
end (48) of the
housing (46) to tighten or release the locking ring (144) located
therebetween. In the preferred
2S embodiment, the locking ring collar (146) is tightened to between about
8000 to 10,000 ft lbs.
The tightening of the locking ring collar (146) holds the locking ring (144)
in position without
increasing the preloading on the proximal tlu-tist bearing (96).
When the locking ring collar (146) is tightened against the locking ring
(144), the
locking ring (144) acts upon the proximal thrust bearing collar (134) to
inhibit the rotation of
the proximal tluwst bearing collar (134) away from the proximal thrust bearing
shoulder (132)
and thus to maintain the preloading. In order to enhance or facilitate the
action of the proximal
tlu-ust bearing retainer (136), the locking ring (144) preferably does not
rotate, or is inhibited
from rotating, relative to the proximal tlu-ust bearing collar (134). This
relative rotation may be
3S prevented or inhibited in any manner and by any stntcture, device or
mechanism capable of
-49-
CA 02569070 2006-12-15
preventing or inhibiting the undesired relative rotation bettveen the locking
ring (144) and the
proximal thl-ust bearing collar (134). However, preferably, the locking ring
(144) is mounted
on the proximal thrust bearing collar ( 134) such that the locking ring ( 144)
does not rotate, or is
1r1111bIted frOIIl rOtattllg, relative to the proximal thrust bearing collar
(134).
The locking ring (144) may be mounted on the proximal thrust bearing collar
( 134) in any manner and by any structure, device or mechanism capable of
preventing or
inhibiting the undesired relative rotation between the locking ring (144) and
the proximal thrust
bearing collar (134). For instance, in the preferred embodiment, at least one
key and slot
configuration is utilized. Specifically, a key (147) extends between a slot or
groove defined by
each of the adjacent surfaces of the locking ring ( 144) and the proximal
thrust bearing collar
(134).
In addition, in order to further enhance or facilitate the action of the
proximal
thrust bearing retainer (136), the locking ring (144) preferably does not
rotate, or is inhibited
from rotating, relative to the housing (46). This relative rotation may be
prevented or inhibited
in any manner and by any structure, device or mechanism capable of preventing
or inhibiting
the undesired relative rotation between the locking ring (144) and the housing
(46). However,
preferably, the configurations of the adjacent abutting surfaces of the
locking ring (144) and the
housing (46) are complementary such that the locking ring (144) does not
rotate, or is inhibited
from rotating, relative to the housing (=46).
In the preferred embodiment, the locking ring ( 144) is further comprised of a
housing abutment surface ( 1 ~2). In addition, the housing (46), and in
particular the proximal
end (58) of the proximal housing section (52), is further comprised of a
locking ring abutment
surface (154). The locking ring abutment surface (154) is complementary to the
housing
abutment surface ( 152) such that the engagement of the housing abutment
surface ( 152) and the
locking ring abutment surface (1~4) prevents or i1W ibits the rotation of the
locking ring (144)
relative to the housing (46). Although any complementary surface
configurations may be used,
the locking ring abutment surface (154) and the housing abutment surface (152)
each preferably
define a plurality of complementary interlocking teeth.
As indicated above, the device (20) includes a drilling shaft deflection
assembly
(92), contained lVIt11111 the hOLlSlllg (46), for bending the drilling shaft
(24) as previously
described. The deflection assembly (92) may be comprised of any structure,
device,
-50-
CA 02569070 2006-12-15
mechanism or method capable of bending the drilling shaft (24) or deflecting
the drilling shaft
(24) laterally or radially w lthm the housing (46) in the described mariner.
However, preferably,
the deflection assembly (92) is comprised of a double ring eccentric
mechanism. Although
these eccentric rings may be located a spaced distance apart along the length
of the drilling
shaft (24), preferably, the deflection assembly (92) is comprised of an
eccentric outer ring (156)
and an eccentric inner ring (158) provided at a single location or position
along the drilling
shaft (24). The rotation of the ttvo eccentric rings (156, 158) imparts a
controlled deflection of
the drilling shaft (24) at the location of the deflection assembly (92).
The preferred deflection assembly (92) of the within invention is similar to
the
double eccentric harmonic drive mechanism described in United States of
America Patent No.
5,353,884 issued October 11, 1994 to Misawa et. al. and United States of
America Patent No.
5,875,859 issued March 2, 1999 to Ikeda et, al., as discussed above.
Particularly, the outer ring (156) has a circular outer peripheral surface
(160) and
defines therein a circular inner peripheral surface (162). The outer ring
(156), and preferably
the circular outer peripheral surface (160) of the outer ring (156), is
rotatably supported by or
rotatably mounted on, directly or indirectly, the circular inner peripheral
surface of the housing
(46). Specifically, in the preferred embodiment, the circular outer peripheral
surface (160) is
rotatably supported by or rotatably mounted on the circular inner peripheral
surface (78) of the
distal housing section (56). The circular outer peripheral surface (160) may
be supported or
mounted on the circular inner peripheral surface (78) by any supporting
structure, mechanism
or device permitting the rotation of the outer ring (156) relative to the
housing (46), such as by
a roller bearing mechanism or assembly. Further, in the preferred embodiment,
the outer ring
(156) is rotatably driven by an outer ring drive mechanism (164), as described
below.
The circular inner peripheral surface (162) of the outer ring (156) is formed
and
positioned within the outer ring (156) such that it is eccentric with respect
to the housing (46).
In other words, the circular inner peripheral surface (162) is deviated from
the housing (46) to
provide a desired degree or amount of deviation.
More particularly, the circular inner peripheral surface (78) of the distal
housing
section (56) is centered on the centre of the drilling shaft (24), or the
rotational axis A of the
drilling shaft (24), when the drilling shaft (24) is in an undeflected
condition or the deflection
assembly (92) is inoperative. The circular imler peripheral surface (162) of
the outer ring (156)
-51-
CA 02569070 2006-12-15
is centered on point B which is deviated from the rotational axis of the
drilling shaft (24) by a
distance "e".
Similarly, the inner ring (158) has a circular outer peripheral surface (166)
and
defines therein a circular inner peripheral surface (168). The inner ring
(158), and preferably
the circular outer peripheral surface (166) of the inner ring (158), is
rotatably supported by or
rotatably mounted on, either directly or indirectly, the circular inner
peripheral surface (162) of
the outer ring (156). The circular outer peripheral surface (166) may be
supported by or
mounted on the circular imler peripheral surface (162) by any supporting
structure, mechanism
or device permitting the rotation of the firmer ring (158) relative to the
outer ring (156), such as
by a roller bearing mechanism or assembly. Further, in the preferred
embodiment, the inner
ring (158) is rotatably driven by an inner ring drive mechanism (170), as
described below.
The circular inner peripheral surface (168) of the firmer ring (158) is formed
and
positioned within the inner ring (158) such that it is eccentric with respect
to the circular inner
peripheral surface (162) of the outer ring (156). In other words, the circular
inner peripheral
surface (168) of the firmer ring (158) is deviated from the circular imler
peripheral surface (162)
of the outer ring (156) to provide a desired degree or amount of deviation.
More particularly, the circular imer peripheral surface (168) of the inner
ring
(158) is centered on point C, which is deviated from the centre B of the
circular inner peripheral
surface ( 162) of the outer ring ( 156) by the same distance "e". As
described, preferably, the
degree of deviation of the circular inner peripheral surface (162) of the
outer ring (156) from
the housing (46), defined by distance "e", is substantially equal to the
degree of deviation of the
circular inner peripheral surface (168) of the inner ring (158) from the
circular inner peripheral
surface (162) of the outer ring (156), also defined by distance "e". However,
if desired, the
degrees of deviation may be varied such that they are not substantially equal.
The drilling shaft (24) extends through the circular inner peripheral surface
(168)
of the inner ring (158) and is rotatably supported thereby. The drilling shaft
(24) may be
supported by the circular inner peripheral surface (168) by any supporting
structure, mechanism
or device permitting the rotation of the drilling shaft (24) relative to the
imer ring (158), such
as by a roller bearing mechanism or assembly.
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CA 02569070 2006-12-15
As a result of the above described configuration, the drilling shaft (24) may
be
moved, and specifically may be laterally or radially deviated within the
housing (46), upon the
movement of the centre of the circular imler peripheral surface (168) of the
imler ring (158).
Specifically, L1p011 the rotation of the inner and outer rings (158, 156),
either independently or
together, the centre of the drilling shaft (24) may be moved with the centre
of the circular inner
peripheral surface (168) of the imier ring (158) and positioned at any point
within a circle
having a radius summed up by the amounts of deviation of the circular inner
peripheral surface
(168) of the lIlllel' ring (158) and the circular inner peripheral surface
(162) of the outer ring
(156). As a result, the drilling shaft (24) is deflected, bent or caused to
curve to produce the
desired toolface and amount of deviation of the drilling bit (22).
In other words, by rotating the inner and outer rings (158, 156) relative to
each
other, the centre of the circular inner peripheral surface (168) of the inner
ring (158) can be
moved in any position within a circle having the predetermined or predefined
radius as
described above. Thus, the poution or section of the drilling shaft (24)
extending through and
supported by the circular inner peripheral surface (168) of the imzer ring
(158) can be deflected
by an amount in any direction perpendicular to the rotational axis of the
drilling shaft (24). As
a result, the drilling direction may be controlled by varying the toolface and
deviation of the
drilling bit (22) comiected with the drilling shaft (24). In this instance,
the device (20) is in a
deflection mode or is set at a "Deflection ON" setting.
More particularly, since the circular firmer peripheral surface (162) of the
outer
ring (156) has the centre B, which is deviated from the rotational centre A of
the drilling shaft
(24) by the distance "e", the locus of the centre B is represented by a circle
having a radius "e"
around the centre A. Further, since the circular inner peripheral surface
(168) of the inner ring
(158) has the centre C, which is deviated from the centre B by a distance "e",
the locus of the
centre "C" is represented by a circle having a radius "e" around the centre B.
As a result, the
centre C may be moved in any desired position within a circle having a radius
of "2e" around
the centre A. Accordingly, the portion of the drilling shaft (24) supported by
the circular inner
peripheral surface (168) of the inner ring (158) can be deflected in any
direction on a plane
perpendicular to the rotational axis of the drilling shaft (24) by a distance
of up to "2e".
In addition, as stated, the deviation distances "e" are preferably
substantially
similar in order to permit the operation of the device (20) such that the
drilling shaft (24) is
undeflected within the housing (24) when directional drilling is not required.
More
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CA 02569070 2006-12-15
particularly, since the degree of deviation of each of the centres B and C of
the circular inner
peripheral surface (162) of the outer ring (156) and the circular imler
peripheral surface (168) of
the inner ring (158) respectively is defined by the same or equal distance
"e", the centre C of
the portion of the drilling shaft (24) extending tlu~ough the deflection
assembly (92) can be
positioned on the rotational axis A of the drilling shaft (24). In this
instance, the device (20) is
in a zero deflection mode or is set at a "Deflection OFF" setting.
The imier and outer ring drive mechanisms ( 170, 164) of the inner and outer
rings (158, 156) respectively may each be comprised of any drive system or
mechanism able to
rotate the respective imier and outer rings (158, 156). However, preferably,
each of the inner
and outer ring drive mechanisms (170, 164) rotates the inner and outer rings
(158, 156)
respectively using the rotation of the drilling shaft (24). In the preferred
embodiment, each of
the inner and outer ring drive mechanisms ( 170, 164) is comprised of a
harmonic drive
mechanism for rotating the inner and outer rings (158, 156) about their
respective axes relative
to each other.
More preferably, the haI'1'IlOtllC drive mechanisms (170, 164) are of the
hollow
type arranged coaxially relative to each other and spaced apau longitudinally
such that the drive
mechanisms (170, 164) are located on opposing sides of the deflection assembly
(92). In other
words, the deflection assembly (92) is located between the harmonic firmer and
outer ring drive
mechanisms ( 170, 164). For instance, in the preferred embodiment, the outer
ring drive
mechanism (64) is located or positioned uphole or proximally of the deflection
assembly (92),
while the inner ring drive mechanism (170) is located or positioned downltole
or distally of the
deflection assembly (92). Thus, the drilling shaft (24) is arranged such that
it extends through
the circular inner peripheral surface (168) of the firmer ring (158) and
through the hollow
portions provided by each of the harmonic firmer and outer ring drive
mechanisms (170, 164).
In the preferred embodiment, the harmonic outer ring drive mechanism (164) is
comprised of first and second rigid circular splines ( 172, 174), a circular
flexible spline or
flexispline ( 176) arranged inside of the rigid circular splines ( 172, 174)
and an elliptical-or oval
shaped wave generator (178) ar-anged inside the circular flexispline (176).
The wave generator
(178) is comprised of a rigid elliptical or oval shaped cam plate (180)
enclosed in a bearing
mechanism or assembly (182). Thus, the bearing mechanism (182) is inserted
between the cam
plate ( 180) and the flexispline ( 176). The drilling shaft (24) is inserted
through the centre of the
cam plate (180) such that an amount of clearance is provided therebetween.
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CA 02569070 2006-12-15
The rigid circular splines (172, 174) have internal spline teeth for engaging
the
external spline teeth of the flexispline (176). The rigid circular splines
(172, 174) have slightly
different numbers of teeth, which internal spline teeth are simultaneously
engaged by the
S external spline teeth of the flexispline (I76).
In the preferred embodiment, the flexispline (176) is provided with less teeth
than the fn-st rigid circular spline (172), preferably two less teeth. The
first rigid circular spline
(172) is fixedly mounted or connected, directly or indirectly, with the inner
surface of the
housing (G4). In the preferred embodiment, the second rigid circular spline
(174) has the same
number of teeth as the flexispline (176) and is connected with the outer ring
(156) so that the
second rigid spline (174) and the outer ring (1S6) rotate integrally or as a
unit.
When the wave generator (178) is inserted into the flexispline (176), it
imparts
1S its elliptical shape to the flexispline (176), causing the external teeth
of the flexispline (176) to
engage with the internal teeth of the rigid circular splines (172, 174) at nvo
equally spaced areas
1 SO degrees apart on their respective circumferences, being the major
elliptical axis of the ~.vave
generator (I78). As a result, a positive gear mesh is formed at the points of
engagement.
Further, as the wave generator (178) rotates in a first direction, the points
of engagement travel
with the major elliptical axis of the wave generator (178). Due to the
differences in the number
of teeth of the flexispline (176) and the first rigid circular spline (172),
when the wave
generator (178) has fumed 180 degrees, the flexispline (176) has regressed
relative to the first
rigid spline (172), typically by one tooth where the flexispline (176)
includes t<vo less teeth.
Thus, each turn or rotation of the wave generator (178) in the first direction
moves or rotates
2S the flexispline (176) in an opposing second direction on the first rigid
circular spline (172),
such as by two teeth where the flexispline (176) includes two less teeth. The
second rigid
circular spline (174), having the same number of teeth as the flexispline
(176), also rotates in
the opposing second direction relative to the first rigid circular spline
(172) at the same rate as
the flexispline (176).
The wave generator (178) thus provides a high speed input, the first rigid
circular
spline (172) is fixed to the housing (46) and thus does not rotate relative to
the housing (46),
and the second rigid circular spline (174) rotates relative to the first rigid
circular spline (172)
and the housing (46) to provide a low speed output.
3S
-SS-
CA 02569070 2006-12-15
Further, the wave generator (178) is directly linked to the drilling shaft
(24)
through an outer ring clutch or clutch mechanism (184), preferably being
electromagnetic, and
a first Oldham coupling (186). Operation of the clutch mechanism (184) causes
a transfer of
the rotational force of the drilling shaft (24) to the harmonic outer ring
drive mechanism (164).
As a result, the outer ring (156) will rotate after the reduction of rotation
at a certain level of
reduction ratio as determined by the harmonic outer ring drive mechanism (164)
as described
above.
ThtlS, tile Outer rlllg drlVe mechanlSln (164) rotates the outer ring (156)
using the
rotation of the drilling shaft (24). The outer drive mechanism (164) is
comprised of the outer
ring clutch (184) for selectively engaging and disengaging the drilling shaft
(24) from the outer
ring (156). The outer ring clutch (184) may be comprised of any clutch or
clutch mechanism
able to selectively engage and disengage the drilling shaft (24) from the
outer ring (156). In
addition, preferably the outer ring clutch (184) is comprised of a clutch and
brake mechanism
such that the outer ring clutch ( 184) performs a dual function.
Preferably, the outer ring clutch (184) is comprised of a pair of clutch
plates
(188) which are separated by a clutch gap (190) when the clutch (184) is
disengaged.
Alternately, the clutch plates (188) are engaged or come together when the
clutch (184) is
engaged to selectively engage the drilling shaft (24) with the outer ring
(156). Thus, the clutch
plates (188) are engaged to engage the drilling shaft (24) with the outer ring
(156) to permit the
rotation of the drilling shaft (24) to rotate the outer ring (156). In
addition, when the clutch
plates (188) are disengaged, the clutch plate (188) associated with the outer
ring (156) acts to
inhibit or prevent the rotation of the outer ring (156) and thus performs a
braking function.
Preferably, the outer ring clutch (184) is comprised of a clutch adjustment
mechanism (192) for adjusting the clutch gap (190). Any mechanism, structure,
device or
method capable of adjusting or facilitating the adjustment of the clutch gap
(190) may be used.
However, preferably, the clutch adjustment Inechalllslll (192) is comprised of
a clutch
adjustment member (194) associated with one of the pair of clutch plates (188)
such that
movement of the clutch adjustment member (194) will result in corresponding
movement of the
associated clutch plate (188) to increase or decrease the clutch gap (190).
Further, the clutch
adjustment IIleChaI11SI11 (192) is comprised of a first guide (196) for
guiding the clutch
adjustment member (192) for movement in a first direction. Finally, the clutch
adjustment
mechanism (192) is comprised of a movable key (198) associated with the clutch
adjustment
-S 6-
CA 02569070 2006-12-15
member (194), wherein the key (198) comprises a second guide (200) for urging
the clutch
adjustment member (194) in a second direction.
The second direction has a component parallel to the first guide (196) and has
a
component perpendicular to the first guide (196). One of the parallel
component and the
perpendicular component is parallel to a direction of movement of the clutch
plate (188)
necessary to increase or decrease the clutch gap (190).
In the preferred embodiment, the first guide (196) guides the clutch
adjustment
member ( I94) for movement in the first direction which is perpendicular to
the direction of
movement of the clutch plate (188). The second guide (200) urges the clutch
adjustment
member (194) in the second direction, wherein the second direction has a
component parallel to
the first guide (I96) and has a component perpendicular to the first guide
(196). Therefore, in
the preferred embodiment, the component parallel to the first guide (196) is
perpendicular to the
direction of movement of the clutch plate (188). The component perpendicular
to the first
guide (196) is parallel to the direction of movement of the clutch plate
(188).
The clutch adjustment member (194) may be associated with the movable key
(198) in any manner and by any mechanism, device or structure such that
movement of the key
(198) results in a corresponding movement of the clutch adjustment member
(194). More
particularly, as a result of the second guide (200), movement of the key (198)
results in
movement of the clutch adjustment member (194) in the second direction.
Preferably, the clutch adjustment member (194) is connected, mounted or
integrally formed with the key (198) such that the member (194) extends
therefrom. In the
preferred embodiment, the clutch adjustment member (194) is integrally formed
with the key
(198) to provide a single unit or element.
The first guide (196) may be comprised of any mechanism, device or structure
able to guide the clutch adjustment member (194) for movement in the first
direction.
Preferably, the first guide (196) is affixed, connected or otherwise
associated with one of the
clutch plates (188). In the preferred embodiment, the first guide (196) is
comprised of a first
slot (I97). More particularly, the first slot (197) is defined by the clutch
plate (188). The first
slot (197) extends circumferentially in the clutch plate (188) and is thus
substantially
perpendicular to the direction of movement of the clutch plate (188).
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CA 02569070 2006-12-15
As indicated, the clutch adjustment member (194) is associated with one of the
clutch plates (188). Specifically, in the preferred embodiment, the clutch
adjustment member
(194) is associated v~~ith the first slot (197) defined by the clutch plate
(188). More particularly,
the clutch adjustment member (194) extends from the key (198) for receipt
within the first slot
(197) such that the member (194) engages the first slot (197).
The second guide (200) may be comprised of any mechanism, device or structure
able to urge the clutch adjustment member (194) in the second direction. In
the preferred
embodiment, the key (198) is positioned in a cavity (20G) defined by the outer
ring drive
mechanism (164) such that the clutch adjustment member (194) may extend from
the key (198)
for engagement with the first slot (197). Further, the key (198) is preferably
comprised of a
sloped or ramp surface (204) oriented in the second direction. Similarly, the
cavity (206)
preferably defines a sloped or ramp surface (208) complementary to the key
ramp surface
(204). In the preferred embodiment, the second guide (200) is comprised of the
key ramp
surface (204) and the cavity ramp surface (208).
Further, the clutch adjustment mechanism (192) is preferably comprised of a
clutch adjustment control meChal115111 (202) for controlling the movement of
the key (198). The
clutch adjustment control mechanism (202) may be comprised of any device,
structure or
mechanism capable of controlling the movement of the key (198). However,
preferably, the
clutch adjustment control mechanism (202) is comprised of an adjustment screw
connected
with the key (198) and which can be rotated inside a threaded bore to finely
control the
movement of the key (198).
Preferably, adjustment of the adjustment screw acts upon the key (198)
resulting
in the movement of the key (198) in a direction that is substantially
perpendicular to the
longitudinal axis of the device (20). More pal-ticularly, movement of the key
(198) results in
the engagement of the key ramp surface (204) and the cavity ramp surface
(208). As a result,
the second guide (200) preferably converts the movement of the key (198) in a
direction that is
substantially perpendicular to the longitudinal axis of the device (20) to
movement of the key
(198) in the second direction, which in turn causes the clutch adjustment
member (194) to move
in the second direction.
-ss-
CA 02569070 2006-12-15
The component of movement of the key (198) along the cavity ramp surface
(208) V'111c11 1S parallel to the first slot (197) results in the clutch
adjustment member (194)
moving in the first slot (197) without imparting a significant rotational
force to the clutch plate
(188). The COITIpOllerlt of movement of the key (198) along the cavity ramp
surface (208)
which is perpendicular to the first slot (197) results in an increase or
decrease in the clutch gap
(190) by engagement of the clutch adjustment member (194) with the clutch
plate (188),
Once the desired clutch gap (190) is achieved, it is preferable that the
desired
setting be capable of being maintained. Thus, preferably, a clutch adjustment
locking
mechanism (210) is provided for fixing the position of the key (198) so that
the clutch gap
( 190) can be maintained at the desired setting. Any locking mechanism,
structure or device
capable of fixing or maintaining the position of the key (198) relative to the
first guide (196)
may be used. However, preferably, the clutch adjustment locking mechanism
(210) is
comprised of one or more locking or set screws associated with the clutch
adjustment member
(194) v~hich may be tightened to fix or maintain the key (198) at its desired
position within the
cavity (206) such that its further movement is prevented or otherwise
inhibited.
Next, referring to the harmonic imler ring drive mechanism ( 170), the
preferred
harmonic inner ring drive mechanism (170), and its components and structure,
are substantially
similar to the harmonic outer ring drive mechanism (164) as described above.
Thus, the
description provided for the harmonic outer ring drive mechanism (164) is
equally applicable to
the harmonic inner ring drive mechanism (170).
In the preferred embodiment, the harmonic inner ring drive mechanism ( 170) is
comprised of first and second rigid circular splines (212, 214), a circular
flexible spline or
flexispline (216) arranged inside of the rigid circular splines (212, 214) and
an elliptical-or oval
shaped wave generator (218) arranged inside the circular flexispline (216).
The wave generator
(218) is comprised of a rigid elliptical or oval shaped cam plate (220)
enclosed in a bearing
mechanism or assembly (222). Thus, the bearing mechanism (222) is inserted
between the cam
plate (220) and the flexispline (216). The drilling shaft (24) is inserted
through the centre of the
cam plate (220) such that all alllOltllt of clearance is provided
therebetween.
The rigid circular splines (212, 214) have intermal spline teeth for engaging
the
external spline teeth of the flexispline (216). The rigid circular splines
(212, 214) have slightly
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CA 02569070 2006-12-15
different numbers of teeth, which internal spline teeth are simultaneously
engaged by the
external spline teeth of the flexispline (21 G).
In the preferred embodiment, the flexispline (216) is provided with less teeth
than the rigid circular spline (212), preferably two less teeth. The first
rigid circular spline
(212) is fixedly mounted or connected, directly or indirectly, with the inner
surface of the
housing (64). In the preferred embodiment, the second rigid circular spline
(214) has the same
number of teeth as the flexispline (216) and is cortrtected with the inner
ring (158) through an
Oldham type centering coupling (223) so that the rigid spline (214) and the
inner ring (158)
rotate through the Oldham type centering coupling (223) integrally or as a
unit.
When the wave generator (218) is inserted into the flexispline (216), it
imparts
its elliptical shape to the flexispline (216), causing the external teeth of
the flexispline (216) to
engage with the internal teeth of the rigid circular splines (212, 214) at two
equally spaced areas
1 S 180 degrees apart on their respective circumferences, being the major
elliptical axis of the wave
generator (218). As a result, a positive gear mesh is formed at the points of
engagement.
Again, due to the differences in the number of teeth of the flexispline (216)
and the first rigid
circular spline (212), when the wave generator (218) has turned 180 degrees,
the flexispline
(216) has regressed relative to the first rigid circular splines (212). Thus,
each turn or rotation
of the wave generator (218) in the first direction moves or rotates the
flexispline (216) in an
opposing second direction on the first rigid circular spline (212). The second
rigid circular
spline (214), having the same number of teeth as the flexispline (216), also
rotates in the
opposing second direction relative to the first rigid circular spline (212) at
the same rate as the
flexispline (216).
Thus, again, the wave generator (218) thus provides a high speed input, the
first
rigid circular spline (212) is fixed to the housing (46) and thus does not
rotate relative to the
housing (46), and the second rigid circular spline (214) rotates relative to
the first rigid circular
spline (212) and the housing (46) to provide a low speed output.
The wave generator (218) is directly lir~hed to the drilling shaft (24)
through an
imler ring clutch or clutch mechanism (224), preferably being electromagnetic,
and a second
Oldham coupling (226), which are substantially similar to the outer ring
clutch (184) and first
Oldham coupling (186) respectively. Operation of the itmer ring clutch (224)
causes a transfer
of the rotational force of the drilling shaft (24) to the harmonic inner ring
drive mechanism
-60-
CA 02569070 2006-12-15
(170). As a result, the imler ring (158) will rotate after the reduction of
rotation at a certain
level of reduction ratio as determined by the harmonic inner ring drive
mechanism (170) as
described above.
Thus, the inner ring drive mechanism (170) rotates the inner ring (158) also
using the rotation of the drilling shaft (24). The inner ring drive mechanism
(170) is comprised
of the inner ring clutch (224) for selectively engaging and disengaging the
drilling shaft (24)
from the inner ring (158). The firmer ring clutch (224) may also be comprised
of any clutch or
clutch mechanism able to selectively engage and disengage the drilling shaft
(24) from the
inner ring (158). In addition, preferably the inner ring clutch (224) is
comprised of a clutch and
brake mechanism such that the inner ring clutch (224) also performs a dual
function.
Preferably, the inner ring clutch (224) is similarly comprised of a pair of
clutch
plates (228) which are separated by a clutch gap (230) when the clutch (224)
is disengaged.
Alternately, the clutch plates (228) are engaged or come together when the
clutch (224) is
engaged to selectively engage the drilling shaft (24) with the inner ring
(158) Thus, the clutch
plates (228) are engaged to engage the drilling shaft (24) with the inner ring
(158) to pernlit the
rotation of the drilling shaft (24) to rotate the firmer ring (I58). In
addition, when the clutch
plates (228) are disengaged, the clutch plate (228) associated with the inner
ring (158) acts to
inhibit or prevent the rotation of the inner ring (158) and thus performs a
braking function.
Preferably, the inner ring clutch (224) is comprised of a clutch adjustment
mechanism (232) for adjusting the clutch gap (230). Any mechanism, structure,
device or
method capable of adjusting or facilitating the adjustment of the clutch gap
(230) may be used.
However, preferably, the clutch adjustment mechanism (232) is comprised of a
clutch
adjustment member (234) associated with one of the pair of clutch plates (228)
such that
movement of the clutch adjustment member (234) will result in corresponding
movement of the
associated clutch plate (228) to increase or decrease the clutch gap (230).
Further, the clutch
adjustment mechanism (232) is comprised of a first guide (236) for guiding the
clutch
adjustment member (232) for movement in a first direction. Finally, the clutch
adjustment
mechanism (232) is comprised of a movable key (238) associated with the clutch
adjustment
member (234), wherein the key (238) comprises a second guide (240) for urging
the clutch
adjustment member (234) in a second direction.
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CA 02569070 2006-12-15
The second direction has a component parallel to the first guide (236) and has
a
component perpendicular to the first guide (236). One of the parallel
component and the
perpendicular component is parallel to a direction of movement of the clutch
plate (228)
necessary to increase or decrease the clutch gap (230).
In the preferred embodiment, the first guide (236) guides the clutch
adjustment
member (234) for movement in the first direction which is perpendicular to the
direction of
movement of the clutch plate (228). The second guide (240) urges the clutch
adjustment
member (234) in the second direction, wherein the second direction has a
component parallel to
the first guide (236) and has a component perpendicular to the first guide
(236). Therefore, in
the preferred embodiment, the component parallel to the first guide (236) is
perpendicular to the
direction of movement of the clutch plate (22$). The component perpendicular
to the first
guide (236) is parallel to the direction of movement of the clutch plate
(228).
The clutch adjustment member (234) may be associated with the movable key
(238) in any manner and by any mechanism, device or structure such that
movement of the key
(238) results in a corresponding movement of the clutch adjustment member
(234). More
particularly, as a result of the second guide (240), movement of the key (238)
results in
movement of the clutch adjustment member (234) in the second direction.
Preferably, the clutch adjustment member (234) is connected, mounted or
integrally formed with the key (238) such that the member (234) extends
therefrom. In the
preferred embodiment, the clutch adjustment member (234) is integrally formed
with the key
(238) to provide a single unit or element.
The first guide (236) tray be comprised of any mechanism, device or structure
able to guide the clutch adjustment member (234) for movement in the first
direction.
Preferably, the first guide (236) is affixed, connected or otherwise
associated with one of the
clutch plates (228). In the prefen-ed embodiment, the first guide (236) is
comprised of a first
slot (237). More particularly, the first slot (237) is defined by the clutch
plate (228). The first
slot (237) extends circutnferentially in the clutch plate (228) and is thus
substantially
perpendicular to the direction of movement of the clutch plate (228).
As indicated, the clutch adjustment member (234) is associated with one of the
clutch plates (228). Specifically, in the preferred embodiment, the clutch
adjustment member
-62-
CA 02569070 2006-12-15
(234) is associated with the first slot (237) defined by the clutch plate
(228), More particularly,
the clutch adjustment member (234) extends from the key (238) for receipt
within the first slot
(237) SLICK that the member (234) engages the first slot (237).
The second guide (240) may be comprised of any mechanism, device or structure
able to urge the clutch adjustment member (234) in the second direction. In
the preferred
embodiment, the key (238) is positioned in a cavity (246) defined by the inner
ring drive
mechanism (170) such that the clutch adjustment member (234) may extend from
the key (238)
for engagement with the first slot (237). Further, the key (238) is preferably
comprised of a
sloped or ramp surface (244) oriented in the second direction. Similarly, the
cavity (246)
preferably defines a sloped or ramp surface (248) complementary to the key
ramp surface
(244). In the preferred embodiment, the second guide (240) is comprised of the
key ramp
surface (244) and the cavity ramp surface (248).
IS Further, the clutch adjustment mechanism (232) is preferably comprised of a
clutch adjustment control mechanism (242) for controlling the movement of the
key (238). The
clutch adjustment control nleCha1115111 (242) may be comprised of any device,
structure or
mechanism capable of controlling the movement of the key (238). However,
preferably, the
clutch adjustment control mechanism (242) is comprised of an adjustment screw
colmected
with the key (23S) and which can be rotated inside a threaded bore to finely
control the
movement of the key (238).
Preferably, adjustment of the adjustment screw acts upon the key (238)
resulting
in the movement of the key (238) in a direction that is substantially
perpendicular to the
longitudinal axis of the device (20). More particularly, movement of the key
(238) results in
the engagement of the key ramp surface (244) and the cavity ramp surface
(248). As a result,
the second guide (240) preferably converts the movement of the key (238) in a
direction that is
substantially perpendicular to the longitudinal axis of the device (20) to
movement of the key
(238) in the second direction, which in turn causes the clutch adjustment
member (234) to move
in the second direction.
The COIIIpOllellt of movement of the key (238) along the cavity ramp surface
(248) which is parallel to the first slot (237) results in the clutch
adjustment member (234)
nlOVlng in the first slot (237) without imparting a significant rotational
force to the clutch plate
(228). The ConlpOIlellt of 1110Vei17ellt of the key (238) along the cavity
ramp surface (248)
-63-
CA 02569070 2006-12-15
which is perpendicular to the first slot (237) results in an increase or
decrease in the clutch gap
(230) by engagement of the clutch adjustment member (234) with the clutch
plate (228).
Once the desired clutch gap (230) is achieved, it is preferable that the
desired
setting be capable of being maintained. Thus, preferably, a clutch adjustment
locking
mechanism (250) is provided for fixing the position of the key (238) so that
the clutch gap
(230) can be maintained at the desired setting. Any locking 111eCha1115I11,
structure or device
capable of fixing or maintaining the position of the key (238) relative to the
first guide (236)
may be used. However, preferably, the clutch adjustment locking mechanism
(250) is
comprised of one or more locking or set screws associated with the clutch
adjustment member
(234) which may be tightened to fix or maintain the key (238) at its desired
position within the
cavity (246) such that its further movement is prevented or otherwise
inhibited.
Further, as a result of the rotation of the drilling shaft (24) during rotary
drilling,
there will be a tendency for the housing (46) to rotate during the drilling
operation. As a result,
the device (20) is preferably comprised of an anti-rotation device (252)
associated with the
housing (46) for restraining rotation of the housing (46) within the wellbore.
Any type of anti-
rotation device (252) or any mechanism, structure, device or method capable of
restraining or
inhibiting the tendency of the housing (46) to rotate upon rotary drilling may
be used. Further,
one or more such devices (252) may be used as necessary to provide the desired
result.
As well, the device (252) may be associated with any portion of the housing
(46)
including its proximal, central and distal housing sections (52, 54, 56). In
other words, the anti-
rotation device (252) may be located at any location or position along the
length of the housing
(46) between its proximal and distal ends (48, 50). In the preferred
embodiment, the device
(52) is associated with the proximal housing section (52). Finally, the device
(252) may be
associated with the housing (46) in any manner permitting the functioning of
the device (252)
to inhibit or restrain rotation of the housing (46). However, preferably, the
anti-rotation device
(252) is associated with an outer surface of the housing (46), preferably
being the outer surface
(72) of the proximal housing section (52). Specifically, the anti-rotation
device (20) is
preferably positioned on or connected, affixed or mounted with the outer
surface (72).
In a preferred embodiment of the anti-rotation device (252), the device (252)
is
comprised of at least one roller (254) on or associated with the outer surface
(72) of the housing
(46). The roller (254) contacts the wall of the wellbore to slow or inhibit
the turning of the
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CA 02569070 2006-12-15
housing (46) with the drilling shaft (24) while drilling. As well, the roller
(254) preferably
exerts only a slight load. As a result, the axial motion of the drilling
device (20), or the
loIlgItLld1I1a1 motion of the device (20) through the wellbore, is relatively
undisturbed such that
the hOLtStllg (46) is permitted to roll through the wellbore.
In the preferred embodiment, where the rotation restraining device or anti-
rotation device (20) is comprised of at least one roller (254) on the housing
(46), each roller
(254) has an axis of rotation substantially perpendicular to a longitudinal
axis (256)of the
housing (46). Further, each roller (254) is oriented such that it is capable
of rolling about its
axis of rotation in response to a force exerted on the roller (254)
substantially in the direction of
the longitudinal axis (256) of the housing (46). For instance, as a
longitudinal force is exerted
though the drilling string (25) from the surface to the drilling shaft (24) in
order to increase or
decrease the necessary weight on the drilling bit (22), the roller (254) rolls
about its axis to
permit the drilling device (20) to move through the wellbore in either a
downhole or uphole
direction as required.
As indicated, the rotation restraining or anti-rotation device (252) may be
comprised of one or more rollers (254). However, preferably, the anti-rotation
device (252) is
comprised of a plurality of rollers (254) spaced about a circumference of the
housing (46),
being defined by the outer surface of the housing (46), such that the rollers
(254) may engage
the wall of the wellbore. Any number of rollers (254) able to effectively
restrain the rotation of
the housing (46) during drilling to the desired degree may be used.
As indicated, the rollers (254) may be mounted with or positioned about the
circumference of the housing (46) in any manner and by any mechanism,
structure or device.
However, preferably, the rollers (254) are mounted or positioned about the
circumference of the
housing (46) in one or more sets (257)of rollers (254) such that each set
(257)of rollers (254)
has a substantially common axis of rotation which is substantially
perpendicular to the
longitudinal axis (256) of the housing (46). Further, one or more sets (257)
of rollers (254) are
preferably 1110UIlted or positioned axially or longitudinally along the
housing (46) within one or
more rotation restraining carriage assemblies (258).
In the preferred embodiment, the anti-rotation device (252) is comprised of
three
rotation restraining carriage assemblies (258) spaced substantially evenly
about the
circumference of the housing (46). Further, each rotation restraining carriage
assembly (258) is
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CA 02569070 2006-12-15
comprised of tlr-ee sets (257) of rollers (254) spaced axially or
longitudinally along the housing
(46). Finally, each set (257) of rollers (254) is comprised of four coaxial
rollers (254) spaced
side to side.
Each rotation restraining carriage assembly (258) may be mounted, comiected or
affixed with the outer surface of the housing (46) in any manner. In the
preferred embodiment,
the outer surface (72) of the proximal housing section (52) defines a separate
cavity (260)
therein for fixedly or removably receiving each of the can-iage assemblies
(258) therein. The
carnage assembly (258) may be fixedly or removably received in the cavity
(260) and mounted,
connected or otherwise affixed therewith in any manner and by any method,
mechanism,
structure or device able to relatively rigidly maintain the carriage assembly
(258) in the cavity
(260) during the drilling operation.
Further, in order to facilitate the movement of the rollers (254) through the
wellbore and to enhance the rotation restraining action of the rollers (254),
each of the rollers
(254) is preferably capable of movement between a retracted position and an
extended position
in which the roller (254) extends radially trom the housing (4G). Further, the
roller (254) is
preferably biased towards the extended position to enhance or facilitate the
engagement of the
roller (254) with the wellbore. Any method, mechanism, structure or device may
be used for
biasing the roller (254) to the extended position. However, preferably, the
anti-rotation device
(252) is further comprised of a biasing device (262) for biasing the roller
(254) toward the
extended position. In the preferred embodiment, the biasing device (262) is
comprised of at
least one spring which acts, directly or indirectly, between the housing (46)
and the carriage
assembly (258) or the rollers (254). The outwardly biasing force or spring
force may be
selected according to the expected drilling conditions.
Each roller (254) may have any shape or configuration permitting it to roll or
move longitudinally through the wellbore, while also restraining the rotation
of the housing
(46) within the wellbore. Specifically, each roller (254) has a peripheral
surface (264) about its
circumference penlllttlllg it to roll or 1110ve lbI1g11Lldlllally w1t11111 the
wellbore. In addition, the
peripheral surface (264) is preferably comprised of an engagement surface
(266) for engaging
the wall of the wellbore or borehole to restrain rotation of the housing (46).
The engagement
surface (266) may have any shape or configuration able to restrain the
rotation of the housing
(46). However, preferably, the engagement surface (266) is comprised of the
peripheral surface
(264) of the roller (254) being tapered.
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CA 02569070 2006-12-15
In an alternate embodiment of the anti-rotation device (252), the device (252)
is
comprised of at least one piston (268) on or associated with the housing (46),
and specifically
the outer surface (72) of the housing (46). In this instance, the piston (268)
contacts the wall of
the wellbore to slow or inhibit the turning of the housing (46) With the
drilling shaft (24) while
drilling. More particularly, an outer surface (270) of the piston (268)
extends from the housing
(46) for engagement with the wall of the wellbore.
In order to facilitate the placement of the drilling device (20) mthm the
wellbore,
the piston (268) is preferably capable of movement between a retracted
position and an
extended position. In the extended position, the outer surface (270) of the
piston (268) extends
radially from the housing (46) for engagement with the wellbore. In the
retracted position, the
outer surface (270) is moved towards the housing (46) and thus, away from or
out of contact
with the wellbore. Any piston (268) or piston assembly may be used to comprise
the anti-
1 S rotation device (252).
Any device, structure, mechanism or method may be used for actuating the
piston or pistons (268) between the retracted and extended positions. However,
preferably, the
anti-rotation device (252) is comprised of an actuator device (272) for moving
the piston (268)
between the retracted and extended positions. The actuator device (272) may be
driven or
powered in any mamier such as hydraulically or pneumatically. However,
preferably the
actuator device (272) is hydraulically powered. More particularly, in the
preferred
embodiment, the actuator device (272) is comprised of a hydraulic pump,
preferably a
miniature co-axial gear type hydraulic pump, operatively connected with each
piston (268).
As indicated, the rotation restraining or anti-rotation device (252) may be
comprised of one or more pistons (268). However, preferably, the anti-rotation
device (252) is
comprised of a plurality of pistons (268) spaced about the circumference of
the housing (46),
being defined by the outer surface of the housing (46), such that the pistons
(268) may engage
the wall of the wellbore. Any number of pistons (268) able to effectively
restrain the rotation
of the housing (46) during drilling to the desired degree may be used.
As indicated, the pistons (268) may be mounted with or positioned about the
circumference of the housing (46) in any mamier and by any mechanism,
structure or device.
_67_
CA 02569070 2006-12-15
However, preferably, the pistons (268) are mounted or positioned about the
circumference of
the housing (46) within one or more rotation restraining piston arrays (274).
In the prefen-ed embodiment, the antl-rOtat1011 device (252) is comprised of
three
rotation restraining piston arrays (274) spaced s~.~bstantially evenly about
the circumference of
the housing (46). Further, each rotation restraining piston array (274) is
comprised of a
plurality of pistons (268) spaced axially or longitudinally along the housing
(46).
Each rotation restraining piston al-ray (274) may be mounted, connected or
affixed with the outer surface of the housing (46) in any mamler. In addition,
each piston (268)
may be mounted, comlected or affixed with the piston array (274) in any
manner. In the
preferred embodiment, the rotation restraining piston array (274) is
preferably integral with the
outer surface (72) of the proximal housing section (52). Further, each piston
array (274)
defines at least one cavity (276) therein for fixedly or removably receiving
the pistons (268) of
the carriage assembly (274) therein. The pistons (268) comprising each piston
array (274) may
be fixedly or removably received in the respective cavities (276) and mounted,
connected or
otherwise affixed therewith in any manner and b~,~ any method, mechanism,
structure or device
able to relatively rigidly maintain the pistons (268) in the cavity or
cavities (276) during the
drilling operation.
Each piston (268) may have any shape or configuration capable of restraining
the
rotation of the housing (46) ~vIt111I1 the wellbore when in the extended
position. Specifically,
each piston (268) has an outernlost engagement surface (278) for engaging the
wall of the
wellbore or borehole to restrain rotation of the housing (46). The engagement
surface (278)
may have any shape or configuration able to engage the wall of the wellbore
and restrain the
rotation of the housing (46) within the wellbore.
In addition, the drilling device (20) is preferably further comprised of one
or
more seals or sealing assemblies for sealing the distal and proximal ends (50,
48) of the housing
(46) such that the components of the device (20) located therebetween are not
exposed to
various drilling fluids, such as drilling mud. In addition to inhibiting the
entrance of drilling
fluids into the device (20) from outside, the seals or sealing assemblies also
facilitate the
maintenance or retention of desirable lubricating fluids within the device
(20).
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CA 02569070 2006-12-15
Preferably, the device (20) is comprised of a distal seal or sealing assembly
(280)
and a proximal seal or sealing assembly (282). The distal seal (280) is
radially positioned and
provides a rotary seal between the housing (46) and the drilling shaft (24)
at, adjacent or in
proximity to the distal end (50) of the housing (46). Thus, in the preferred
embodiment, the
distal seal (280) is radially positioned and provides a seal between the
drilling shaft (24) and the
distal housing section (56) at, adjacent or in proximity to it distal end
(68).
The proximal seal (282) is radially positioned and provides a rotary seal
between
the housing (46) and the drilling shaft (24) at, adjacent or in proximity to
the proximal end (48)
of the housing (46). However, where the drilling string (25) extends within
the proximal end
(48) of the housing (46), the proximal seal (282) is more particularly
positioned between the
housing (46) and the drilling string (25). Thus, the proximal seal (282) is
radially positioned
and provides a seal between the drilling shaft (24) and the proximal housing
section (52) at,
adjacent or in proximity to it distal end (60). However, more particularly,
the proximal seal
(282) is radially positioned and provides a seal between an outer surface of
the drilling string
(25) and the proximal housing section (52) at, adjacent or in proximity to it
distal end (60).
As well, the interior of the housing (46) preferably defines a fluid chamber
(284)
between the distal and proximal ends (50, 48) of the housing (46). Thus, the
fluid chamber
(284) is positioned or defined between the distal and proximal seals (280,
282) associated with
the distal and proximal ends (50, 48) of the housing (46) respectively. As
indicated above, the
fluid chamber (284) is preferably filled with a lubricating fluid for
lubricating the components
of the device (20) within the housing (46).
In addition, one or both of the distal seal (280) and the proximal seal (282)
are
also preferably lubricated with the lubricating fluid from the fluid chamber
(284) of the housing
(46). In other words, each of the rotary distal and proximal seals (280, 282)
is lubricated using
fluid, typically oil, from the internal lubricating system of the drilling
device (20). In addition,
as described further below, each of the distal and proximal seals (280, 282)
are lubricated or
provided with filtered fluid in order to prevent or minimize any damage to the
seals (280, 282)
from any damaging metallic particles or other damaging contaminants which may
be found
tt~1tI1111 the lubricating fluid frOtn the fluid chamber (284) of the housing
(46) of the device (20).
By filtering the lubricating fluid passing from the fluid chamber (284) of the
housing (46) into
either or both of the distal and proximal seals (280, 282), a relatively clean
fluid environment is
provided for the seals (280, 282).
-69-
CA 02569070 2006-12-15
As well, the distal and proximal seals (280, 282) are preferably mounted about
the drilling shaft (24) and drilling string (25) respectively such that the
drilling shaft (24) and
attached drilling string (25) are permitted to rotate therein while
maintaining the sealing.
Further, the distal and proximal seals (280, 282) preferably provide a
flexible sealing
al-rangement or flexible connection between the housing (46) and the drilling
shaft (24) or
drilling string (25) in order to maintain the seal provided thereby, while
accommodating any
movement or deflection of the drilling shaft (24) or drilling string (25)
within the housing (46).
This flexible connection is particularly important for the distal seal (280)
which is exposed to
the pivoting of the drilling shaft (24) by the deflection assembly (92).
In the preferred embodiment, the distal seal (280) is comprised of an inner
portion (286) fixedly mounted about the drilling shaft (24) at, adjacent or in
proximity to the
distal end (50) of the housing (46) such that the imier portion (286) of the
distal seal (280)
rotates integrally with the drilling shaft (24). The distal seal (280) is
further comprised of an
outer portion (288), a section or pal-t of which is rotatably mounted about
the inner portion
(286) to permit relative rotation therebetween and such that a charnel or
space (290) is defined
between the inner and outer portions (286, 288). Further, the outer portion
(288) is fixedly
mounted, directly or indirectly, with the distal end (50) of the housing (46).
Thus, upon the
rotation of the drilling shaft (24), the inner portion (286) rotates with the
drilling shaft (24)
relative to the outer portion (288) which remains substantially stationary
with the housing (46).
Any structure, mechanism or device may be used to permit the relative rotation
between the
inner and outer portions (286, 288) of the distal seal (280). However, in the
preferred
embodiment, one or more bearings (292) are located between the inner and outer
portions (286,
288) within the channel or space (290). Preferably, the bearings (292) are
angular contact
thrust bearings which serve a dual function as both radial and thl-ust
bearings.
As indicated, the outer portion (288) of the distal seal (280) is fixedly
mounted,
directly or indirectly, with the distal end (50) of the housing (46). However,
in the preferred
embodiment, the outer portion (288) is fixedly connected or mounted with the
distal thrust
bearing collar ( 110) which 1S fixedly colmected or Illoullted with the distal
end (50) of the
housing (46). Accordingly, the distal seal (280) is located or positioned
adjacent the distal end
(50) of the housing (46) within the distal thrust bearing retainer (112).
-70-
CA 02569070 2006-12-15
In addition, in the preferred embodiment, the outer portion (288) is comprised
of
a flexible collar (294) which provides the flexible connection or flexible
sealing arrangement to
accommodate the deflection or pivoting of the drilling shaft (24) within the
housing (46). The
flexible collar (294) is particularly located adjacent the point of connection
of the outer portion
(288) of the distal seal (280) with the distal thrust bearing collar (110). As
a result, upon
deflection of the drilling shaft (24), the imler portion (286) of the distal
seal (280) and the
section or part of the outer portion (288) mounted about the imler portion
(286) are permitted to
pivot about the point of connection of the outer portion (288) with the distal
thrust bearing
collar ( 110).
The distal seal (280) is further comprised of at least two rotary seals (298,
300)
located within the channel or space (290) between the inner and outer portions
(286, 288) of the
distal seal (280) such that a chamber (296) is defined therebetween. Fluid is
provided within
the chamber (296) for lubricating the components of the distal seal (280).
Preferably, the distal
seal (280) is further comprised of a distal filtering mechanism for filtering
the lubricating fluid
from the fluid chamber (284) of the housing (46) so that the distal seal (280)
is lubricated with
filtered lubricating fluid. Any structure, mechanism, device or method may be
used which is
capable of filtering the lubricating fluid entering the distal seal (280).
However, in the
preferred embodiment, one or more filters (302) are located within the chamber
(296) of the
distal seal (280).
More particularly, an upper internal wiper seal (298) defines the uppermost or
proximal end of the chamber (296). In addition, at least one filter (302) is
preferably provided
adjacent the internal wiper seal (298). As indicated, the distal seal (280) is
preferably
lubricated with the lubricating fluid from the fluid chamber (284) of the
housing (46). In
addition, the fluid is preferably filtered in order to prevent or minimize any
damage to the distal
seal (280) from any damaging metallic particles or other contaminants which
may be found
within the lubricating fluid from the fluid chamber (284) of the housing (46).
Thus, the internal
wiper seal (298) and the filter (302) assist in providing a relatively clean
fluid enviromnent for
the distal seal (280).
In addition, a lower external barrier seal (300) defines the lowermost or
distal
end of the chamber (296). The external barrier seal (300) prevents or inhibits
the passage of
external contaminants and abrasive wellbore material into the distal seal
(280). Thus, the
-71-
CA 02569070 2006-12-15
external banier seal (300) also assists in providing a relatively clean fluid
environment for the
distal seal (280).
Finally, in the preferred embodiment, a rotary face seal (304) is provided
adjacent of the external barrier seal (300) outside of the chamber (296) for
further preventing or
izW ibiting the passage of contaminants and abrasive material from the
welibore into the distal
seal (280). The rotary face seal (304) provides a seal behveen the adjacent
lowermost faces or
distal ends of the izmer and outer poz-lions (286, 288) of the distal seal
(280). Although any
rotary face seal may be used, the rotary face seal (304) is preferably biased
or spring loaded to
maintain the sealing action.
The proximal seal (282) is also comprised of an inner portion (306) fixedly
mounted about the drilling string (25) at, adjacent or in proximity to the
proximal end (48) of
the housing (46) such that the inner portion (306) of the proximal seal (282)
rotates integrally
with the drilling string (25) and the drilling shaft (24). The proximal seal
(2$2) is further
comprised of an outer portion (308), a section or part of which is rotatably
mounted about the
inner portion (306) to permit relative rotation therebetween and such that a
channel or space
(310) is defined between the inzzer and outer portions (306, 308). Further,
the outer portion
(308) is fixedly mounted, directly or indirectly, with the proximal end (48)
of the housing (46).
Thus, upon the rotation of the drilling strzng (25), the inner portion (306)
rotates with the
drilling string (25) relative to the outer portion (308) which remains
substantially stationary
with the housing (46). .Any shl.zcture, mechanism or device may be used to
permit the relative
rotation between the firmer and outer portions (306, 308) of the proximal seal
(282). However,
in the preferred embodiment, one or more bearings (312) are located between
the inner and
outer portions (306, 308) within the channel or space (310). Preferably, the
bearings (312) are
angular contact thrust bearings which serve a dual function as both radial and
thrust bearings.
As indicated, the outer portion (308) of the proximal seal (282) is fixedly
mounted, directly or indirectly, with the proximal end (48) of the housing
(46). However, in
the preferred embodiment, the outer portion (308) is fixedly connected or
mounted with the
proximal thz-ust bearing collar (134) which is fixedly cozmected or mounted
with the proximal
end (48) of the housing (46). Accordingly, the proximal seal (282) is located
or positioned
adjacent the proximal end (48) of the housing (46) within the proximal thrust
bearing retainer
(136).
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CA 02569070 2006-12-15
In addition, in the preferred embodiment, the outer portion (308) is comprised
of
a flexible collar (314) which provides the flexible connection or flexible
sealing arrangement to
accommodate any movement or deflection of the drilling sting (25) within the
housing (46).
The flexible collar (314) is particularly located adjacent the point of
colmection of the outer
portion (308) of the proximal seal (282) with the proximal tlu-ust bearing
collar (134). As a
result, LlpoIl deflection of the drilling string (25), the inner portion (306)
of the proximal seal
(282) and the section or part of the outer portion (308) mounted about the
inner portion (306)
are permitted to pivot about the point of connection of the outer portion
(308) with the proximal
tlu-ust bearing collar ( 134).
The proximal seal (282) is further comprised of at least two rotary seals
(318,
320) located within the channel or space (310) between the inner and outer
portions (306, 308)
of the proximal seal (282) such that a chamber (316) is defined therebetween.
Fluid is provided
within the chamber (316) for lubricating the components of the proximal seal
(282).
Preferably, the proximal seal (282) is further comprised of a proximal
filtering mechanism for
filtering the lubricating fluid from the fluid chamber (284) of the housing
(46) so that the
proximal seal (282) is lubricated with filtered lubricating fluid. Any
structure, mechanism,
device or method may be used which is capable of filtering the lubricating
fluid entering the
proximal seal (282). However, in the preferred embodiment, one or more filters
(322) are
located \i'lthlll the Challlber (316) of the proximal seal (282).
More particularly, a lower internal wiper seal (318) defines the lowermost or
distal end of the chamber (316). In addition, at least one filter (322) is
preferably provided
adjacent the internal wiper seal (318). As indicated, the proximal seal (282)
is preferably
lubricated with the lubricating fluid from the fluid chamber (284) of the
housing (46). In
addition, the fluid is preferably filtered in order to prevent or minimize any
damage to the
proximal seal (282) from any damaging metallic particles or other contaminants
which may be
found within the lubricating fluid fiom the fluid chamber (284) of the housing
(46). Thus, the
internal wiper seal (318) and the filter (322) assist in providing a
relatively clean fluid
environment for the proximal seal (282).
In addition, an upper external barrier seal (320) defines the uppermost or
proximal end of the chamber (316). The external barrier seal (320) prevents or
inhibits the
passage of external contaminants and abrasive wellbore material into the
proximal seal (282).
-73-
CA 02569070 2006-12-15
Thus, the external barrier seal (320) also assists in providing a relatively
clean fluid
envirotunent for the proximal seal (282).
Finally, in the prefen-ed embodiment, a rotary face seal (324) is provided
adjacent of the external barrier seal (320) outside of the chamber (316) for
further preventing or
iWibiting the passage of contaminants and abrasive material from the wellbore
into the
proximal seal (282). The rotary face sea( (324) provides a seal between the
adjacent uppermost
faces or proximal ends of the imer and outer poutions (306, 308) of the
proximal seal (282).
Although any rotary. face seal may be used, the rotary face seal (324) is
preferably biased or
spring loaded to maintain the sealing action.
Further, the lubricating fluid contained within the fluid chamber (284) of the
housing (46) between the proximal and distal seals (282, 280) has a pressure.
Preferably, the
device (20) is further comprised of a pressure compensation system (326) for
balancing the
pressure of the lubricating fluid contained in the fluid chamber (284) within
the housing (46)
with the ambient pressure outside of the housing (46). The pressure
compensation system
(326) may be located at any position or location along the length of the
housing (46) between
the distal and proximal seals (280, 282). In addition, the pressure
compensation system (326)
may be corrected, mounted or othenvise associated with one or more of the
distal, central and
proximal housing sections (52, ~4, ~6). However, preferably, the pressure
compensation
system (326) is corrected, mounted or othet-wise associated with the central
housing section
(54). More preferably, the pressure compensation system (326) is connected,
mounted or
otherwise associated with the central housing section (54) proximal to or
uphole of the
proximal radial bearing (84).
The pressure compensation system (326) may be comprised of any mechanism,
device or structure capable of providing for or permitting the balancing of
the pressure of the
lubricating fluid contained in the fluid chamber (284) with the ambient
pressure outside of the
housing (46). Preferably, the pressure compensation system (326) is comprised
of at least one
pressure port (328) in the housing (46) so that the ambient pressure outside
of the housing (46)
can be communicated to the fluid chamber (284). In the preferred embodiment, a
pressure port
(328) is located and mounted within the central housing section (S4) to permit
the
COn111111n1CattOIl Of the ambient pressure of the wellbore fluids outside of
the central housing
section (54) to the lubricating fluid within the fluid chamber (284), which is
contained or
defined at least in part by the central housing section (54). Thus, in the
wellbore, the pressure
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CA 02569070 2006-12-15
of the lubricating fluid wltlnn the housing (46) is determined at least in
part by the ambient
pressure outside of the housing (46) within the annulus of the wellbore.
Further, the pressure compensation system (326) is preferably comprised of a
lubricating fluid regulating system (331 ) which facilitates charging of the
fluid chamber (284)
with lubricating fluid and provides adjustment of the amount of lubricating
fluid in the fluid
chamber (284) during drilling in response to increased temperatures and
pressures downhole
experienced by the lubricating fluid.
Preferably, the lubricating fluid regulating system (331) is comprised of a
charging valve (332) and a relief valve (334). Both valves (332, 334) are
located or mounted
within the housing (46), preferably in the central housing section (54). The
charging valve
(332) permits or provides for the entry or charging of a sufficient amount of
the lubricating
fluid into the fluid chamber (284). The relief valve (334) is set to permit
the passage of fluid
out of the fluid chamber (284) tlu-ough the relief valve (334) at a
predetermined or preselected
pressure.
More particularly, the drilling device (20) is charged with lubricating oil at
the
surface tlurough the charging valve (332) until the fluid pressure in the
fluid chamber (284)
exceeds the pressure value of the relief valve (334). In addition, as the
device (20) is moved
downhole in the wellbore and the temperature increases, the fluid expands and
the excess fluid
is ejected or expelled from the fluid chamber (284) through the relief valve
(334).
Preferably, the pressure of the lubricating fluid contained in the fluid
chamber
(284) of the housing (46) is maintained higher than the ambient pressure
outside of the housing
(46) or the annulus pressure in the wellbore. Specifically, the pressure
compensation system
(326) preferably internally maintains a positive pressure across the distal
and proximal seals
(280, 282). As a result, in the event there is any tendency for the distal and
proximal seals
(280, 282) to leak and permit the passage of fluid across the seals (280,
282), the passage of any
such fluid will tend to be lubricating fluid from within the fluid chamber
(284) to outside of the
device (20). Accordingly, the higher internal pressure will facilitate the
maintenance of a clean
fluid envirol>lment within the fluid chamber (284), as described above, by
inhibiting or
preventing the passage of wellbore ammlus fluids into the fluid chamber (284).
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CA 02569070 2006-12-15
In order to provide a pressure within the fluid chamber (284) of the housing
(46)
higher than the outside annulus pressure, the pressure compensation system
(326) is further
preferably comprised of a supplementary pressure source (330). The
supplementary pressure
source (330) exerts pressure on the lubricating fluid contained in the fluid
chamber (284) so that
the pressure of the lubricating fluid contained in the fluid chamber (284) is
maintained higher
than the ambient pressure outside of the housing (46). The pressure
differential between the
fluid chamber (284) and outside the housing (46) lnay be selected according to
the expected
drilling conditions. However, preferably, only a slightly positive pressure is
provided in the
fluid chamber (284) by the supplementary pressure source (330).
The supplementary pressure may be provided in any manner or by any method,
and the supplementary pressure source (330) may be comprised of any structure,
device or
mechanism, capable of providing the desired supplementary pressure within the
fluid chamber
(284) to generate the desired pressure differential between the fluid chamber
(284) and outside
the housing (46). However, preferably, the pressure compensation system (326)
is further
comprised of a balancing piston assembly (336).
The balancing piston assembly (336) is comprised of a piston chamber (338)
defined by the interior of the hOtlSillg (46), preferably the inner surface
(74) of the central
housing section (54). The balancing piston assembly (336) is further comprised
of a movable
piston (340) contained within the piston chamber (338). The piston (340)
separates the piston
chamber (338) into a fluid chamber side (342) and a balancing side (344). The
fluid chamber
side (342) is connected with the fluid chamber (284) and is preferably located
distally or
downhole of the piston (340). The pressure port (328) communicates with the
balancing side
(344) of the piston chamber (338), which is preferably located proximally or
uphole of the
piston (340). Further, the supplementary pressure source (330) acts on the
balancing side (344)
of the piston chamber (338). Specifically, the supplementary pressure source
(330) acts on the
balancing side (344) by exel-ting the supplementary pressure on the piston
(340).
In the prefel-red eillbOdllllellt, the Supple111elltary presSUre SollrCe (330)
is
comprised of a biasing device located within the balancing side (344) of the
piston chamber
(338) and which exerts the supplementary pressure on the piston (340). More
particularly, the
biasing device biases the piston (340) distally or downhole to generate or
exert the
supplementary pressure within the fluid chamber side (342) of the piston
chamber (338), which
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CA 02569070 2006-12-15
supplementary pressure is connnunicated to the lubricating fluid within the
fluid chamber (284)
of the hOllslllg (46).
Thus, the supplementary pressure source (330) may be comprised of any device,
structure or mechanism capable of biasing the piston (340) in the mamler
described above.
However, in the preferred embodiment, the biasing device is comprised of a
spring (346). As
indicated, the spring (346) is contained in the balancing side (344) of the
piston chamber (338).
When charging the device (20) with lubricating oil, the spring (346) is
preferably fully
compressed. As lubricating oil leaks or otherwise passes out of the fluid
chamber (284), the
spring (346) continues to exert the supplementary pressure on the piston (340)
and the piston
(340) is moved distally or in a downhole direction.
As a safety provision, an indicator is preferably provided with the device
(20) for
indicating the level of the lubricating oil in the fluid chamber (284) and
communicating this
information to the surface. Preferably, a two position switch is provided
which indicates a
"low" oil level and "no" oil level. This allows the device (20) to be pulled
from the wellbore in
the case of an oil leak, while avoiding or minimizing any damage to the device
(20).
In the preferred embodiment, the pressure compensation system (326) is further
comprised of an oil level limit switch (348). The oil level limit switch (348)
is preferably
positioned within the fluid chamber side (342) of the piston chamber (338).
Specifically, as the
oil is depleted and the level thus decreases within the fluid chamber (284),
the spring (346)
exerts the supplementary pressure on the piston (340) and the piston (340) is
moved distally or
in a downhole direction within the piston chamber (338) towards the oil level
limit switch
(348). Once the oil is depleted to a preselected level, or the oil is fully
depleted, the piston
(340) is moved within the piston chamber (338) for contact with and depression
or movement
of the oil level limit switch (348) distally in a downhole direction.
Depression of the oil level
limit switch (348) actuates the oil level limit switch (348) to indicate
either a "low oil level" or
"no oil level" in the fluid chamber (284) depending upon the amount or extent
to which the
switch (348) is depressed.
In the prefen-ed embodiment of the device (20), there is a need to communicate
electrical signals between two members which rotate relative to each other
without having any
contact therebetween. For example, this communication is required when
downloading
operating parameters for the device (20) or communicating do~vnhole
information from the
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CA 02569070 2006-12-15
device (20) either further uphole along the drilling string (25) or to the
surface. Specifically,
the electrical signals must be communicated between the drilling shaft (24)
and the housing
(46), which rotate relative to each other during the rotary drilling
operation.
The communication link between the drilling shaft (24) and the housing (46)
may be provided by any direct or indirect coupling or communication method or
any
mechanism, structure or device for directly or indirectly coupling the
drilling shaft (24) with the
housing (46). For instance, the communication between the housing (46) and the
drilling shaft
(24) may be provided by a slip ring or a gamma-at-bit communication toroid
coupler.
However, in the preferred embodiment, the communication between the drilling
shaft (24) and
the housing (46) is provided by an electromagnetic coupling device.
In the preferred embodiment, the communication between the drilling shaft (24)
and the housing (46) is provided by an electromagnetic coupling device (350).
More
particularly, the electromagnetic coupling device (350) is comprised of a
housing conductor or
coupler (352) positioned on the housing (46) and fixedly mounted or connected
with the
housing (46) such that it remains substantially stationary relative to the
drilling shaft (24)
during drilling. Fuuther, the electromagnetic coupling device (350) is
comprised of a drilling
shaft conductor or coupler (354) positioned on the drilling shaft (24) and
fixedly mounted or
connected with the drilling shaft (24) such that the drilling shaft conductor
(354) rotates with
the drilling shaft (24). The housing conductor (352) and the drilling shaft
conductor (354) are
positioned on the housing (46) and drilling shaft (24) respectively
sufficiently close to each
other so that electrical signals may be induced between them.
The housing conductor (352) and the drilling shaft conductor (354) may be
comprised of a single wire or a coil and may be either wrapped or not wrapped
around a
magnetically permeable core.
Further, in the preferred eIllbOdlIllellt, proximal electrical conductors,
such as
proximal electrical wires (356), run or extend along or through the drilling
string (25) to the
drilling shaft (24) within the de~~ice (20) to the drilling shaft conductor
(354). Similarly, distal
electrical conductors, such as distal electrical wires (358), run or extend
from the housing
conductor- (352) along or through the housing (46) to a controller (360) of
the device (20) and to
the various sensors as outlined below.
_~8_
CA 02569070 2006-12-15
The electromagnetic coupling device (350) may be positioned at any location
along the length of the device (20). However, in the prefeled embodiment, the
electromagnetic
coupling device (350) is positioned or located within the central housing
section (54). More
pal-ticularly, the electromagnetic coupling device (350) is positioned or
located wlthln the
central housing section (54) at, adjacent or in proximity to its proximal end
(62), proximal to or
uphole of the proximal radial bearing (84) and the pressure compensation
system (326).
The deflection assembly (92) may be actuated manually. However, as indicated,
the device (20) is preferably further comprised of a controller (360) for
controlling the actuation
of the drilling shaft deflection assembly (92) to provide directional drilling
control. The
controller (360) of the device (20) is associated with the housing (46) and is
preferably
comprised of an electronics insect positioned within the central housing
section (54). More
preferably, the controller (360), and particularly the electronics insert, is
positioned within the
central housing section (54) distal to or downhole of the proximal radial
bearing (84):
Information or data provided by the various downllole sensors of the device
(20) is
communicated to the controller (360) in order that the deflection assembly
(92) may be actuated
with reference to and in accordance with the information or data provided by
the sensors.
More particularly, the deflection assembly (92) is preferably actuated to
orient
the inner and outer rings (158, 1~6) relative to a reference orientation in
order to provide
directional control over the drilling bit (22) during drilling operations. In
the preferred
embodiment, the deflection assembly (92) is actuated with reference to the
orientation of the
housing (46) in the wellbore.
Thus, the drilling device (20) is preferably comprised of a housing
orientation
sensor apparatus (362) which is associated with the housing (46) for sensing
the orientation of
the housing (46) within the wellbore. Given that the housing (46) is
substantially restrained
from rotating during drilling, the orientation of the housing (46) which is
sensed by the housing
orientation sensor apparatus (362) provides the reference orientation for the
device (20). The
hollSlllg orientation sensor apparatus (362) may be comprised of any sensor or
sensors, such as
one or a combination of magnetometers and accelerometers, capable of sensing
the position of
the housing at a location at, adjacent or in proximity to the distal end (60)
of the housing (46).
More pal-ticularly, the hOLlSlllg orientation sensor apparatus (362) is
preferably located as close
as possible to the distal end (50) of the housing (46). In addition, the
housing orientation sensor
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CA 02569070 2006-12-15
apparatus (362) preferably senses the orientation of the housing (46) in three
dimensions in
space.
In the preferred embodiment, the housing orientation sensor apparatus (362) is
contained within or comprised of an ABI or At-Bit-Inclination insert (364)
associated with the
housing (46). Preferably, the ABI insert (364) is connected or mounted with
the distal housing
section (56) at, adjacent or in close prOxlllllty lvlth 1tS distal end (68).
In the preferred
embodiment, the ABI insert (364) is positioned or located within the distal
housing section (56)
axially between the deflection assembly (92) and the fulcrum bearing (88).
As well, the drilling device (20) is preferably further comprised of a
deflection
assembly orientation sensor apparatus (366) which is associated with the
deflection assembly
(92) for sensing the orientation of the deflection assembly (92). More
particularly, the
deflection assembly orientation sensor apparatus (366) senses the particular
orientation of the
inner and outer rings (158, 156) of the deflection assembly (92) relative to
the housing (46).
The deflection assembly orientation sensor apparatus (366) may be comprised of
any sensor or sensors, such as one or a combination of magnetometers and
accelerometers,
capable of sensing the position of the deflection assembly (92) relative to
the housing (46). In
addition, the deflection assembly orientation sensor apparatus (366)
preferably senses the
orientation of the deflection assembly (92) in three dimensions in space.
Where one sensor is
provided, the sensor must be capable of sensing the orientation of the inner
peripheral surface
(168) of the inner ring (158) relative to the housing (46). However,
preferably, the deflection
assembly orientation sensor apparatus (366) is comprised of a separate sensor
for sensing the
orientation of each of the inner ring (158) and the outer ring (156) relative
to the housing (46).
In the preferred embodiment, the deflection assembly orientation sensor
apparatus (366) is comprised of an inner ring home reference sensor (368) for
sensing the
orientation of the inner ring (158) relative to the housing (46) and an outer
ring home reference
sensor (370) for sensing the orientation of the outer ring (156) relative to
the housing (46). The
inner and outer ring home reference sensors (368, 370) may be associated with
the respective
inner and outer rings ( 1 S 8, 1 S 6) in any mamZer and by any structure,
mechanism or device
permitting or capable of providing For the sensing of the orientation of the
associated ring (158,
156) by the respective sensor (368, 370). However, preferably, the inner and
outer ring home
reference sensors (368, 370) are mounted or connected with the inner ring
drive mechanism
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CA 02569070 2006-12-15
(170) and the outer ring drive mechanism (164) respectively. In addition, each
of the imier and
outer ring home reference sensors (368, 370) provides information or data to
the controller
(360) with respect to the orientation of the respective rings (158, 156) as
compared to a home or
reference position relative to the housing (46).
In the preferred embodiment, each of the imler and outer ring home reference
sensors (368, 370) is comprised of a plurality of magnets associated with a
rotating or rotatable
component of the imler ring drive mechanism (170) and the outer ring drive
mechanism (164)
respectively such that the magnets rotate therewith. The magnetic fields
generated by the
magnets of each of the inner and outer ring home reference sensors (368, 370)
are sensed by a
stationary counter associated with a non-rotating or non-rotatable component
of the inner ring
drive mechanism (170) and the outer ring drive mechanism (164) respectively.
The stationary
counter is provided to sense how far the inner and outer rings (158, 156) have
rotated from each
of their reference or home positions.
In addition, the deflection assembly orientation sensor apparatus (366) may
also
be comprised of one or more position sensors, such as high speed position
sensors, associated
with each of the inner and outer ring drive mechanisms (170, 164). In the
preferred
embodiment, the deflection assembly orientation sensor apparatus (366) is
comprised of an
iiu~er ring high speed position sensor (372) associated with the izuzer ring
drive mechanism
(170) and an outer ring high speed position sensor (374) associated with the
outer ring drive
mechanism (164). Each of the high speed sensors (372, 374) is provided for
sensing the
rotation which is actually transmitted from the drilling shaft (24) through
the inner ring clutch
(224) and outer ring clutch (184) respectively to the inner and outer ring
drive mechanisms
(170, 164) respectively.
The inner and outer ring high speed position sensors (372, 374) may be
associated with the respective izmer and outer ring drive mechanisms (170,
164) in any manner
and by any structure, mechanism or device permitting the sensing of the
rotation actually
transmitted from the drilling shaft (24) tlu~ough the clutch (224, 184) to the
drive mechanisms
(170, 164). However, preferably, the izmer and outer ring high speed position
sensors (372,
374) are mounted or connected with the izmer ring drive mechanism (170) and
the outer ring
drive mechanism (164) respectively.
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CA 02569070 2006-12-15
In addition, one and preferably both of the high speed position sensors (372,
374)
may be associated with an tpm sensor (375). The tptn sensor (375) is
connected, mounted or
associated with the drilling shaft (24) for sensing the rotation of the
drilling shaft (24). In the
preferred embodiment, the rpm sensor (375) is positioned within the central
housing section
(54) adjacent the electromagnetic coupling device (350). Further, the rpm
sensor (375) is
associated with the high speed position sensors (372, 374) such that a
comparison may be made
between the rotation sensed by the high speed position sensors (372, 374) and
the rotation
sensed by the rpm sensor (375). The comparison of the rotation sensed by the
high speed
position sensors (372, 374) and the rotation sensed by the rpm sensor (375)
may be used to
determine slippage through one or both clutches (224, 184) and to detect
possible
malfunctioning of the clutch (224, 184).
Each of the inner and outer ring high speed position sensors (372, 374) may
similarly be comprised of any sensor or sensors capable of sensing rotation as
described above.
As indicated, the controller (360) is operatively connected with both the
housing
orientation sensor apparatus (362) and the deflection assembly orientation
sensor apparatus
(366) so that the deflection assembly (92) may be actuated with reference to
the orientation of
both the housing (46) and the deflection assembly (92).
The deflection assembly (92) is preferably actuated with reference to the
orientation of both the
housing (46) and the deflection assembly (92) since the housing orientation
sensor apparatus
(362) preferably senses the orientation of the housing (46) in three-
dimensional space, while the
deflection assembly orientation sensor apparatus (366) preferably senses the
orientation of the
inner and outer rings (158, I56) of the deflection assembly (92) relative to
the housing (46).
Although the controller (360) may be operatively connected with both the
housing orientation sensor apparatus (362) and the deflection assembly
orientation sensor
apparatus (366) in any manner and by any mechanism, structure, device or
method permitting
or providing for the communication of information or data therebetween, the
operative
COtIIleCt1011 1S preferably provided by an electrical conductor, such as
electrical wiring.
The controller (360) may also be operatively cortrtected with a dt~illing
string
orientation sensor apparatus (376) so that the deflection assembly (92) may
further be actuated
with reference to the orientation of the drilling string (25). The drilling
string orientation sensor
apparatus (376) is connected, mounted or othei~vise associated with the
drilling string (25).
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CA 02569070 2006-12-15
The controller (360) may be operatively connected with the drilling string
orientation sensor
apparatus (376) in any manner and by any mechanism, structure, device or
method permitting
or providing for the communication of information or data therebetween.
However, preferably, the operative connection between the controller (360) and
the drilling string orientation sensor apparatus (376) is provided by the
electromagnetic
coupling device (350). Specifically, as discussed above, the distal wires
(358) extend from the
controller (360) to the housing conductor (352) of the electromagnetic
coupling device (350).
The proximal wires (356) preferably extend along the drilling string (25) from
the drilling
string orientation sensor apparatus (376) to the drilling shaft (24) and the
drilling shaft
conductor (354). Electrical signals are induced between the housing conductor
(352) and the
drilling shaft conductor (354).
The drilling string orientation sensor apparatus (376) may be comprised of any
sensor or sensors, such as one or a combination of magnetometers and
accelerometers, capable
of sensing the orientation of the drilling string (25). In addition, the
drilling string orientation
sensor apparatus (376) preferably senses the orientation of the drilling
string (2~) in three
dimensions in space.
Thus, in the preferred embodiment, the deflection assembly (92) may be
actuated
to reflect a desired orientation of the drilling string (25) by taking into
consideration the
orientation of the drilling string (25), the orientation of the housing (46)
and the orientation of
the deflection assembly (92) relative to the housing (46).
As well, while drilling, the housing (46) may tend to slowly rotate in the
same
direction of rotation of the drilling shaft (24) due to the small amount of
torque that is
transmitted from the drilling shaft (24) to the housing (46). This motion
causes the toolface of
the drilling bit (22) to move out of the desired position. The various sensor
apparatuses (362,
366, 376) sense this change and communicate the information to the controller
(360). The
controller (360) preferably keeps the toolface of the drilling bit (22) on
target by automatically
rotating the imler and outer rings (158, 156) of the deflection assembly (92)
to compensate for
the rotation of the housing (46).
Further, in order that information or data may be communicated along the
3~ drilling string (25) fr0111 Or to dow nhole locations, such as from or to
the controller (360) of the
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CA 02569070 2006-12-15
device (20), the device (20) may be comprised of a drilling string
communication system (378).
More particularly, the drilling string orientation sensor apparatus (376) is
also preferably
operatively comtected with the drilling string communication system (378) so
that the
orientation of the drilling string (25) may be CO111111L1I11Cated to an
operator of the device (20).
The operator of the device (20) may be either a person at the surface in
charge or control of the
drilling operations or may be comprised of a computer or other operating
system for the device
(20).
The drilling string CO1111nL1111Cat1017 SySte111 (378) may be comprised of any
system
able to communicate or transmit data or information from or to downhole
locations. However,
preferably, the drilling string communication system (378) is comprised of an
MWD or
Measurement-While-Drilling system or device.
The device (20) may be comprised of any further number of sensors as required
or desired for any particular drilling operation, such as sensors for
monitoring other internal
parameters of the device (20).
Finally, the device (20) may be filrther comprised of a device memory (380)
for
storing data generated by one or more of the housing orientation sensor
apparatus (362), the
deflection assembly orientation sensor apparatus (366), the drilling string
orientation sensor
apparatus (376) or data obtained from some other source such as, for example
an operator of the
device (20). The device memory (380) is preferably associated with the
controller (20), but
rnay be positioned anywhere between the proximal and distal ends (48, 50) of
the housing (46),
along the drilling string (25), or may even be located outside of the
borehole. During operation
of the device (20), data may be retrieved from the device memory (380) as
needed in order to
COlltrol the operation of the device (20), including the actuation of the
deflection assembly (92).
The invention is also comprised of methods for orienting a drilling system,
which methods are pal-ticularly suited for orienting a rotary drilling system
and are preferably
used for directional drilling using a rotary drilling system, The methods of
the within invention
may be used for rotary drilling with any rotary drilling system comprised of a
rotatable drilling
string (25) and a drilling direction control device.
Further, the methods may be used for rotary drilling with any drilling
direction
control device which includes a rotatable and deflectable dnllmg shaft (24)
connected with the
_84_
CA 02569070 2006-12-15
drilling string (2s). The deflection of the drilling shaft (24) may be
achieved by bending the
drilling shaft (24) or by pivoting the drilling shaft (24) or by a combination
thereof.
However, preferably, the methods of the within invention are used and
s performed in conjunction with the drilling direction control device (20)
described herein, and
more preferably, with the preferred embodiment of the drilling direction
control device (20).
The methods may be perfornled manually or on a fully automated or semi-
automated basis.
Where the methods are performed manually, an operator of the device provides
instructions to the drilling direction control device (20) for actuation of
the device (20), which
instructions may be communicated to the device (20) via a drilling string
communication
system (378). In other words, where the methods are performed manually, there
is a
communication link between the operator and the device (20).
1 s Where the methods are perforned on either a fully automated basis or a
semi-
automated basis, the operator does not cormnunicate with or provide
instructions to the device
(20). Instead, the drilling string communication system (378) communicates
with the device
(20) and provides instructions to the device (20) for actuation of the device
(20). In other
words, where the methods are performed on an automated basis, there is no
communication link
?0 between the operator and the device (20), although there may be a
communication lint: between
the operator and the drilling string communication system (378).
Where the method is fully automated, the operator of the device typically
provides no instructions to either the device (20) or the drilling string
communication system
2s (378) other than to provide the initial programming of the device (20) or
any subsequent
reprogramming (20), and the device (20) and the drilling string communication
system (378)
communicate with each other to control the direction of drilling.
Where the method is semi-automated, the operator of the device (20)
30 conmnunicates with the drilling string communication system (378), which
then provides
instructions to the device (20) to control the direction of drilling. The
communication between
the operator and the drilling string communication system (378) may be
conducted in any
manner. In the preferred embodiment, the operator communicates with the
drilling string
communication system (378) by manipulating the drilling string (2s). The
drilling string
-ss-
CA 02569070 2006-12-15
communication system (378) then provides instructions to the device (20) based
upon the
communication between the operator and the drilling string communication
system (378).
Regardless of whether the method is being performed on a manual, fully
automated or semi-automated basis, 111StrL1Ct1011S 111L1St S0117ehow be
provided to the device (20)
to actuate the device (20) to deflect the drilling shaft (24).
If the operator or the drilling StTlllg CO111muri1Cat10n Sy5teI11 (378)
provide
instructions to the device (20) relating specifically to a required actuation
of the device (20),
then the instructions are being provided directly to the device (20).
Conversely, if the operator
or the drilling string communication system (378) provide instructions to the
device (20)
relating only to the desired orientation of the drilling string (25) or to
some other parameter,
then the instructions are being provided indirectly to the device (20), since
the instructions
pertaining to the orientation of the drilling string (25) or other parameter
must be processed by
the device (20) and converted to instructions relating specifically to the
required actuation of
the device (20) to reflect the desired orientation of the drilling string.
For instance, the methods may be performed manually and directly by the
operator providing inst111ctions to the drilling direction control device (20)
relating specifically
to a required actuation of the device (20). Specifically, the operator of the
device (20) may
receive data from various sensors pertaining to the orientation of the
drilling string (25) or the
device (20). The operator may then process this data and provide specific
instructions to the
device (20) relating to the actuation of the device (20) required to achieve a
desired orientation
of the drilling shaft.
Alternatively, the methods may be performed manually and indirectly by the
operator providing lllStrL1Ct10I'IS to the device (20) relating only to the
desired orientation of the
drilling string (25). Specifically, the operator of the device (20) may
receive data from a sensor
or sensors pertaining to the orientation of the drilling string (25). The
operator may then
provide to the device (20) instructions in the form of the data pertaining to
the desired
orientation of the drilling string (25), which the device (20) may then
process and convert to
specific instructions far actuation of the device to reflect the desired
orientation of the drilling
string (25).
_8~_
CA 02569070 2006-12-15
The methods may be perforn'ted semi-automatically and directly by the operator
communicating with the drilling string communication system (378), such as for
example by
111alllpulatlon of the drilling string (25). The drllhllg Strlllg
COl11mu111Cat10I1 Systelll (378) then
gathers data, processes the data and generates instructions to provide to the
device (20) relating
specifically to a required actuation of the device (20), which instructions
are communicated
from the drilling string communication system (378) to the device (20).
Alternatively, the methods may be perfol-tned semi-automatically and
indirectly
by the operator communicating with the drilling string communication system
(378), such as
for example by manipulation of the drilling string (25). The drilling string
communication
system (378) gathers data and then generates instnlctions to provide to the
device (20) in the
form of data relating to a parameter such as the orientation of the drilling
string (25), which
instructions are communicated from the drilling string communication system
(378) to the
device (20). The device (20) then processes the instructions to actuate the
device (20) to reflect
1 S the instructions received from the drilling string conllnunication system
(378).
The methods may be performed fillly automatically and directly by the drilling
string communication system (378) gathering data, processing the data and
generating
insttllctions to the device (20) relating specifically to a required actuation
of the device (20),
which instnlctions are communicated from the drilling string communication
system (378) to
the device (20).
Alternatively, the methods Inay be performed fillly automatically and
indirectly
by the drilling string communication system (378) gathering data and
generating instructions to
provide to the device (20) in the form of data relating to a parameter such as
the orientation of
the drilling string (25), which instructions are communicated from the
drilling string
communication system (378) to the device (20). The device (20) then processes
the
instructions to actuate the device (20) to reflect the instnlctions received
from the drilling string
communication system (378).
However, as noted above, where the method is fully automated, the method
involves pre-programming one or both of the drilling Slrlllg COnln1ul11CatlOn
System (378) alld
the device (20) prior to commencing the drilling operation. Further or
alternatively, the method
may involve programming or reprogramming one or both of the drilling stl-ing
communication
system (378) and the device (20) during or after commencement of the drilling
operation.
_87_
CA 02569070 2006-12-15
For instance, when the methods are performed fully automatically and
indirectly,
the methods preferably involve pre-programming the device (20) with a desired
orientation of
the drilling string (25) or a series of desired orientations of the drilling
string (25). The device
(20) then communicates with the drilling string communication system (378) to
effect drilling
for a pre-programmed duration at one desired orientation of the drilling
string (25), followed by
drilling for a pre-programmed duration at a second desired orientation of the
drilling string
(25), and so on. In addition, the methods may further or alternately involve
programming or
reprogramming the device (20) with a new or further desired orientation of the
drilling string
(25) or a new or further series of desired orientations of the drilling string
(25) during the
drilling operation. In this case, the new or further desired orientations may
be sent to the device
memory (380) and stored for subsequent retrieval.
The device (20) may also be operated using a combination of fully automated
IllethOdS, 5et111-alltOlllated methods and manual methods, and may be assisted
by expert systems
and artificial intelligence (AI) to address actual drilling conditions that
are different from the
expected drilling conditions.
In the preferred embodiment, the methods are performed semi-automatically and
indirectly. Thus, as described above, the device (20) is preferably used in
conjunction with the
drilling string communication system (378). Furthermore, the device is
preferably capable of
interfacing with the system (378) such that it can communicate with the
drilling string
communication system (378) and process data generated by the drilling string
communication
system (378) in order to control the actuation of the device (20). The
drilling string
communication system (378) may thus be used to communicate data provided by
one or more
of the sensor apparatuses (3G2, 3GG, 376) or other downhole sensors to the
surface and may
further be used to communicate data or information dowWole to the drilling
direction control
device (20).
As indicated, where the method is performed semi-automatically and indirectly,
the operator communicates with the drilling string COII1111uI11CatI0I1 S}~Stem
(378) only and not
with the device (20). The operator preferably communicates with the drilling
string
communication system (378) by IllallipLllatlllg the drilling string (25) to a
desired orientation.
Thus, the preferred embodiment of the method allows the operator of the
drilling system to be
concerned primarily with the orientation of the drilling string (25) during
drilling operations,
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CA 02569070 2006-12-15
since the device (20) will interface with the drilling string communication
system (378) and
adjust the deflection assembly (92) with reference to the orientation of the
drilling string (25).
This is made possible by establishing a relationship amongst the orientation
of the drilling
string (25), the orientation of the housing (46) and the orientation of the
deflection assembly
(92), thus simplifying drilling operations.
Further, operation of the drilling direction control device (20) on an
indirect,
semi-automated basis preferably involves establishing or detenrlining a
desired orientation of
the drilling string (25) before the commencement of drilling operations and
actuating the
drilling direction control device (20), and particularly the deflection
assembly (92), to deflect
the drilling shaft (24) to reflect the desired orientation. This desired
orientation is then
preferably maintained until a new desired orientation is established and will
typically require
temporary cessation of drilling to permit the deflection assembly (92) to be
actuated to reflect
the new desired orientation of the drilling string (25).
In addition, operation of the drilling direction control device (20) also
preferably
I11vO1veS I11a111ta1I11I1g the deflection of the drilling shaft (24) during
drilling operations so that
the deflection of the drilling shaft (24) continues to reflect the desired
orientation of the drilling
string. Maintaining the deflection of the drilling shaft (24) results in the
maintenance of both
the toolface and the magnitude of deflection of the drilling bit (22) attached
thereto.
In the preferred embodiment, the maintaining step may be necessary where some
rotation of the housing (46) of the device (20) is experienced during drilling
operations and
may involve adjusting deflection of the drilling shaft (25) to account for the
rotation of the
housing (46) during drilling operations or to adjust the actuation of the
deflection assembly (92)
to account for rotational displacement of the housing (46), since the
deflection assembly (92) in
the preferred embodiment is actuated relative to the housing (46). In
addition, the actuation of
the deflection assembly (92) may also require adjusting to account for
undesired slippage of
one or both of the roller and outer ring clutches (224, 184) comprising the
inner and outer ring
drive mechanisms (170, 164) of the deflection assembly (92).
More particularly, in the preferred embodiment, the method is comprised of the
steps of orienting the drilling string (25) at a desired orientation, sensing
the desired
Orlelltatloll Of tile dr1111I1g StrlIlg (25) with the drilling stung con
lmunication system (378),
COI11111u111Catlllg the desired orientation of the drilling string (25) to the
drilling direction
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CA 02569070 2006-12-15
control device (20) and actuating the drilling direction control device (20)
to deflect the
drilling shaft (24) to reflect the desired orientation. The deflection of the
drilling shaft (24)
provides the necessary or required toolface and magnitude of deflection of the
drilling bit (22)
attached to the drilling shaft (24) such that the drilling operation may
proceed in the desired
direction and the drilling direction may be controlled.
The drilling string (25) may be oriented at the desired orientation, and
specifically the orienting step may be performed, in any mariner and by any
method able to
achieve the desired orientation of the drilling string (25). However,
preferably, the drilling
string (25) is manipulated from the surface to achieve the desired
orientation. Further, in the
preferred eIllbOdlIIletlt, the orienting step is comprised of comparing a
current orientation of the
drilling string (25) with the desired orientation of the drilling string (25)
and rotating the
drilling string (25) to eliminate any discrepancy between the current
orientation and the desired
orientation.
Once the desired orientation of the drilling string (25) is achieved by
manipulation of the drilling string (2~), the desired orientation is then
communicated to the
device (20). The desired orientation may be communicated to the device (20)
either from the
surface of the wellbore or from a drilling string orientation sensor apparatus
(376) located
somewhere on the dl'llllIl~ string (25).
More particularly, the drilling string ot~ientation sensor apparatus (376) is
preferably associated with the drilling string communication system (378) and
the
communicating step is performed by communicating the desired orientation from
the drilling
string communication system (378) to the device (20). In other words, the
operator manipulates
the drilling string (25) to communicate the desired orientation to the
drilling stung
communication system (378). The drilling string communication system (378)
then generates
instructions to provide to the device (20) in the form of data relating to the
desired orientation
of the drilling string (25), which instructions are communicated from the
drilling string
communication system (378) to the device (20) to perforn the communicating
step.
The drilling direction control device (20) is then actuated to deflect the
drilling
shaft (24) to reflect the desired orientation. In the preferred embodiment,
the device (20)
receives the 111StrLICtlotl5 COII1111L1I11Cated from the drilling string
communication system (378)
and processes the instructions to actuate the device (20). More particularly,
the device (20)
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CA 02569070 2006-12-15
processes the instructions provided in the form of data relating to the
desired orientation of the
drilling string (25) and converts those instructions into instructions
relating specifically to the
required actuation of the device (20), and particularly the deflection
assembly (92), to reflect
the desired orientation.
Thus, the device (20) is actuated to reflect the desired orientation by
actuating
the device (20) to account for the relative positions of the drilling string
(25) and the device
(20). Preferably, the device (20) is actuated to reflect the desired
orientation by accounting for
the relative positions of the drilling string (25) and the housing (46) and
the deflection assembly
(92) comprising the device (20).
The drilling direction control device (20) tnay be actuated in any manner and
may be powered separately from the rotary drilling system. However, in the
preferred
embodiment, the device (20), and in particular the deflection assembly (92),
is actuated by
rotation of the drilling string (25) as described in detail above. Thus, in
the preferred
embodiment, the actuating step is comprised of rotating the drilling string
(25).
Further, the method is preferably comprised of the further step of
periodically
communicating the current orientation of the drilling string (25) to the
drilling direction control
device (20). The current orientation may be periodically communicated in any
manner and at
any spaced intervals. However, the current orientation of the drilling string
(25) is preferably
periodically communicated to the drilling direction control device (20) after
a predetermined
delay. In addition, the step of periodically communicating the current
orientation of the drilling
string (25) to the device (20) is preferably comprised of periodically
communicating the current
orientation of the drilling string (25) from the drilling string communication
system (378) to the
device (20).
Thus, the actuating step is preferably comprised of waiting for a period of
time
equal to or greater than the predetermined delay once the drilling string (25)
is oriented at the
desired orientation so that the desired orientation of the drilling string
(25) is communicated to
the device (20) and then rotating the drilling string (25) to actuate the
device (20) to reflect the
desired orientation of the drilling string (25).
Finally, as described previously, the device (20) is further preferably
comprised
of the device memory (380). In this instance, the method is preferably further
comprised of the
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CA 02569070 2006-12-15
step Of storing the can ~ent orientation of the drilling Strlng (25) In the
device memory (380)
when it is communicated to the device (20).
Further, in this instance where the device (20) includes a device memory
(380),
the actuating step is preferably further comprised of the steps of retrieving
from the device
memory (380) the curt -ent orientation of the drilling string (25) most
recently stored in the
device memory (380) and then rotating the drilling string (25) to actuate the
device (20) to
reflect the most recent cun-ent orientation of the drilling string (25) stored
in the device memory
(380).
Finally, in the preferred embodiment, the method comprises the step of
maintaining the deflection of the drilling shaft (24) to reflect the desired
orientation of the
drilling string (25) during operation of the rotary drilling system.
Preferably, the orientation
maintaining step is comprised of communicating the current orientation of the
drilling string
(25) from the drilling string communication system (378) to the device (20)
and actuating the
device (20) to adjust the deflection of the drilling shaft (24) to reflect the
desired orientation of
the drilling string (25) and the curt -ent orientation of the drilling shaft
(24).
In a first applied example relating to the above preferred method, the steps
set
out below are performed.
First, the circulation or flow rate of drilling fluid through the drilling
string (25)
and the rotation speed or rprm of the drilling string (25) are both permitted
to fall or drop below
a predetermined threshold value for a discrete period of time. For instance,
preferably, the
circulation and rotation are both simultaneously at zero for a discrete period
of time.
Second, with the drilling string (25) rotation speed held below the threshold
value, and preferably held at zero, the pumping of drilling fluid down the
drilling string (25) is
commenced and subsequently increased to a rate at which the MWD apparatus
(378) registers,
via a pressure sensor, that circulation is occurring. This information then
passes from the
MWD apparatus (378) to the device (20). The device (20) recognizes that the
drilling shaft (24)
running through it is not rotating and selects a'Deflection ON' setting.
Third, shouly after it first senses circulation, the MWD apparatus (378)
begins to
acquire current 1\~t~VD toolface values or cutTent drilling string (25)
orientation values, which it
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CA 02569070 2006-12-15
pulses to surface. After a predetermined period of time, preferably one
minute, has elapsed, the
MWD apparatus (378) also begins to send MWD toolface values or current
drilling string (25)
orientation values to the device (20). However, these values are only sent
after they have
reached a predetermined age, preferably 30 seconds.
Fourth, the operator at surface monitors the current MWD toolface or drilling
string (25) orientation. If the displayed value or orientation is not either
equal to or sufficiently
close to the required value or desired drilling string (25) orientation, then
the operator rotates
the drilling string (25) through an appropriate angle and awaits an update of
the orientation
from the MWD apparatus (378).
Fifth, when the operator is satisfied that the current MWD toolface value or
the
current orientation of the drilling string (25) is in accordance with the
desired orientation, the
predetel-mined period of time, being 1 minute, is allowed to elapse before
continuous drilling
string (25) rotation is commenced. This ensures that the 30 second old
toolfaee or orientation
of the drilling string (25) stored in the device memory (380) of the device
(20) is identical to the
MWD toolface or orientation of the drilling string (2~) displayed at surface.
Sixth, commencement of continuous drilling string (25) rotation instructs the
device (20) to accept the toolface or current orientation of the drilling
string (25), currently
stored in its memory (380), as the toolface or desired orientation required
during drilling.
Alternately, the method may be comprised of the steps of communicating a
desired orientation of the drilling string (25) to the drilling direction
control device (20) and
actuating the device (20) to deflect the drilling shaft (24) to reflect the
desired orientation. The
desired orientation may be communicated to the device (20) either from the
surface of the
wellbore or from a drilling string orientation sensor apparatus (376) located
somewhere on the
drilling string (25).
More particularly, in the alternate embodiment, the drilling string
orientation
sensor apparatus (376) is preferably associated v~ith the drilling string
communication system
(378) and the communicating step is performed by communicating the desired
orientation from
the drilling string C0111111u111Cat1011 SySteill (378) to the device (20). In
other words, the operator
manipulates the drilling string (25) to communicate the desired orientation to
the drilling string
3J co1111I1u111Cat1011 SyStelll (378). The drilling StrIIlg
CO1I1111uI11Cat1011 SYSte121 (378) then generates
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CA 02569070 2006-12-15
instructions to provide to the device (20) in the form of data relating to the
desired orientation
of the drilling string (25), which instructions are communicated from the
drilling string
COIIIIIIllnlCat1011 SyStelll (378) to the device (20) to perform the
communicating step.
The drilling direction control device (20) is then actuated to deflect the
drilling
shaft (24) to reflect the desired orientation. The device (20) receives the
instructions
COlI1n1L1n1Cated frOn7 the drilling string communication system (378) and
processes the
instructions to actuate the device (20). More pal-ticularly, the device (20)
processes the
instructions provided in the form of data relating to the desired orientation
of the drilling string
(25) and C011vertS thOSe 111St11,1Ct10I1S IIltO 111St111Ct10nS relatlng
specifically to the required
actuation of the device (20), and particularly the deflection assembly (92),
to reflect the desired
orlentatlon.
Thus, the device (20) is actuated to reflect the desired orientation by
actuating
the device (20) to account for the relative positions of the drilling string
(25) and the device
(20). Preferably, the device (20) is actuated to reflect the desired
orientation by accounting for
the relative positions of the drilling string (25) and the housing (46) and
the deflection assembly
(92) comprising the device (20).
The drilling direction control device (20) may be actuated in any manner and
may be powered separately from the rotary drilling system. However,
preferably, the device
(20), and in particular the deflection assembly (92), is actuated by rotation
of the drilling string
(25) as described in detail above. Thus, the actuating step is comprised of
rotating the drilling
string (25).
Further, the alternate method is preferably comprised of the further step of
periodically comrrlunicating the current orientation of the drilling string
(25) to the drilling
direction control device (20). The cul-rent orientation may be periodically
communicated in any
manner and at any spaced inten~als. However, the current orientation of the
drilling string (25)
is preferably periodically C011111111111Cated to the drilling direction
control device (20) after a
predetel-lnined delay. In addition, the step of periodically communicating the
current
orientation of the drilling Strlllg (25) to the device (20) is preferably
comprised of periodically
communicating the cul-rent orientation of the drilling string (25) from the
drilling string
communication system (37S) to the device (20).
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CA 02569070 2006-12-15
In the alternate embodiment, the actuating step is preferably comprised of
waiting for a period of time less than the predetermined delay so that the
current orientation of
the drilling string (25) is not communicated to the device (20) and then
rotating the drilling
string (25) to actuate the device (20) to reflect the desired orientation.
Finally, the alternate method is preferably further comprised of the step of
storing the desired orientation of the drilling string (?5) in the device
memory (380) when it is
communicated to the device (20).
IO In this instance, the actuating step is preferably comprised of the steps
of
retrieving from the device memory (380) the desired orientation of the
drilling string (25) and
then rotating the drilling string (25) to actuate the device (20) to reflect
the desired orientation
of the drilling string (25) stored in the device memory (380).
Finally, the alternate method also preferably comprises the step of
maintaining
the deflection of the drilling shaft (24) to reflect the desired orientation
of the drilling string
(25) during operation of the rotary drilling system. Preferably, the
orientation maintaining step
is comprised of communicating the current orientation of the drilling string
(25) from the
drilling string communication system (378) to the device (?0) and actuating
the device (20) to
adjust the deflection of the drilling shaft (24) to reflect the desired
orientation of the drilling
string (25) and the current orientation of the drilling shaft (24).
In a second applied example relating to the above alternate method, the steps
set
out below are performed.
First, the circulation or flow rate of the drilling fluid through the drilling
string
(25) and the rotation speed or rpm of the drilling string (25) are both
permitted to fall or drop
below a predetemrtined threshold value for a discrete period of time. For
instance, preferably,
the circulation and rotation are both simultaneously at zero for a discrete
period of time.
Second, with the drilling string (25) rotation speed held below the threshold
value, preferably at zero, the pumping of drilling fluid down the drilling
string (25) is
commenced and subsequently increased to a rate at which the MWD apparatus
(378) registers,
via a pressure sensor, that circulation is occurring. This information then
passes from the
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CA 02569070 2006-12-15
MWD apparatus (378) to the device (20). The device (20) recognizes that the
drilling shaft (24)
rutming through it is not rotating and selects the 'Deflection ON' setting,
Third, continuous drilling string (25) rotation is then commenced before the
predetermined period of time (preferably one minute) following the
commencement of
circulation, has elapsed. This instructs the device (20) to accept the
toolface or drilling string
(25) orientation cutTently stored in the device memory (380) as the desired
toolface or drilling
string (25) orientation required during drilling. In the event no updated MWD
toolface data or
updated desired drilling string (25) orientation has been written or provided
to the device
memory (380), the toolface or orientation stored prior to the cessation of
rotation and
circulation is maintained as the desired toolface or desired drilling string
(25) orientation
required during drilling.
As well, in the event that it is desired that the deflection assembly (92) not
deflect the drilling shaft (24), thus allowing or providing for the drilling
of a straight wellbore,
in a third specific applied example of the method of the invention, the steps
set out below are
perforrled.
First, the circulation or flow rate of the drilling fluid within the drilling
string
(25) and the rotation speed or rpm of the drilling string (25) are both
permitted to fall or drop
belov,~ a predetermined threshold value for a discrete period of time. Again,
preferably, the
circulation and rotation are both simultaneously at zero for a discrete period
of time.
Second, rotation of the drilling string (25) is commenced and continued for a
discrete period prior to the start of circulation of drilling fluid through
the drilling string (25).
The device (20) recognizes that rotation of the drilling string (25) is
occurring and, in the
absence of prior information froth the MWD apparatus (378) that circulation
has begun, the
device (20) selects the 'Deflection OFF' setting.
From the above three applied examples of the methods of the within invention,
it
can be seen that the device (20) is preferably activated by the sequence and
timing of the
commencement of the rotation of the drill string (25) and the commencement of
the circulation
or flow of drilling fluid wtthln the drill string (25). Further, the device
(20) may be activated by
or configured to respond to any or all of the various permutations or
combinations relating to
the sequence and timing of the commencement of rotation and circulation,
-9G-
CA 02569070 2006-12-15
Further, the device (20) preferably makes enquiries of the drilling stt7ng
communication system (378) upon sensing a change in one or both of the
rotation of the
drilling string (25) and the circulation of drilling fluid. For instance, the
device (20) may make
enquiries upon sensing a change in the state of rotation of the drilling
string (25) above or
below a predetermined threshold value. Further, the device (20) may make
enquiries upon
sensing a change in the state of the circulation of drilling fluid within the
drilling string (25)
above or below a predetermined threshold value.
A further example of a preferred embodiment illustrating from a software
design
perspective how the sequencing and timing of commencing rotation of the
drilling string (25)
and circulating drilling fluid through the drilling string (25) may be used to
effect the actuation
of the device (20) is as follows.
1 ~ First, the device (20) may sense that the rotation of the drilling string
(25) has
fallen below a tl. reshold level such as for example ten revolutions per
minute. The device then
sets a request for circulation status bit which indicates to the drilling
string communication
system (378) that the device (20) wishes to know if circulation of drilling
fluid through the
drilling string (25) is occurnng above a threshold level.
The drilling string communication system (378) preferably reads this status
message from the device (20) about every 1 second and determines that the
device (20) wishes
to know if the threshold level of circulation is occurring. The drilling
string communication
system (378) is also constantly polling all systems linked to the drilling
string communication
system (378) on the communications bus far data and requests for data and
moves this data
around for the various systems including the device (20).
In response to the enquiry from the device (20), the drilling string
communication system (378) inteurogates the pressure sensor which senses
circulation of
drilling fluid and determines whether circulation is in fact occurring at a
level above the
tlueshold level.
The drilling string communication system (378) sends a message to the device
(20) indicating the status of circulation. If the pressure sensed by the
pressure sensor is above
the threshold value then circulation is considered to be "on". If the status
of circulation is "on"
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CA 02569070 2006-12-15
then the device (20) remains actuated at its current orientation if rotation
of the drilling StrlIlg
(25) begins again at a speed above the threshold rotation speed.
If the circulation is considered to be "off' then the device (20) is set in a
state to
receive a possible command causing it to change the actuation position of the
device (20). The
device (20) therefore continues to keep the request for circulation status bit
set so that the
device (20) receives continual periodic updates from the drilling string
communication system
(378) as to the status of circulation.
If rotation of the drilling string (25) above the threshold speed commences
before
circulation of drilling fluid above the threshold level commences then the
device (20) waits and
monitors the circulation status. If circulation commences before a preset time-
out period
(preferably about 10 minutes) expires, then the device (20) actuates to
"Deflection OFF" mode.
If the circulation commences after the time-out period has expired then the
device (20) remains
actuated at its present orientation.
If the request for circulation status bit is set true froIIl false by the
drilling string
communication system (378) (thus indicating that circulation above the
threshold level has
commenced) then the device (20) immediately checks the rotation status to see
if the drilling
string (25) is rotating at a speed higher than the threshold speed.
If the drilling string (25) is rotating at a speed above the threshold level,
then the
device (20) will remain actuated at its current orientation.
If the drilling string (25) is not rotating at a speed above the threshold
level then
the device waits for one of a possible four events to occur. In addition, once
the drilling string
COmI11uI11Cat1011 systelll (378) detects that circulation of drilling fluid is
occurring it begins
logging data pertaining to the orientation of the drilling string (25) and
storing them in the
system memory.
In event l, the rotation of the drilling string (25) commences by going above
the
threshold speed before a preset "RESUME" time-out period has expired. This
RESUME time
out period is preferably about 1 I111nLlte. If event 1 occurs the device (20)
recalls from the
device memory what the previous orientation setting was and actuates to that
setting by
engaging the deflection assembly (92).
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In event 2, the rotation of the drilling string (25) commences by going above
the
threshold speed after the RESUME time out but before a "CANCEL" time out
expires. As
previously indicated, during intervals when the rotation is not occurring
above the threshold
speed but circulation of drilling fluid is occun-ing above the tlu-eshold
level the drilling string
communication system (378) constantly logs and stores data pel-taining to the
orientation of the
drilling string (25).
At the same time the drilling string CO11111111111Cat1011 System (378)
transmits data
pertaining to the orientation of the drilling string (25) to the surface where
the data is displayed
in virtual real-time for the operator to see.
The operator then orients the drilling string (25) to the desired orientation
and
holds the desired orientation steady for a period of time sufficient to ensure
that the desired
orientation of the drilling string (25) has been communicated both to the
surface and to the
device (20) and then preferably for an additional thirty seconds to ensure
that the data
pertaining to the desired orientation of the drilling string (25) is stable.
For example, if the time
required to ensure proper communication of the data is thirty seconds then the
drilling string
(25) is preferably held stationary for at least sixty seconds.
Once the drilling string (25) has been oriented to the desired orientation and
the
proper wait period has expired, then rotation of the drilling string (25) at a
speed above the
threshold speed will result in the device (20) sensing the rotation internally
with its rpm sensor
(375). The device (20) then sets a request for desired orientation flag asking
for a value for the
desired orientation of the drilling string (25). The drilling string
communication system (378)
reads the request message within about 1 second and sends the device (20) data
pertaining to
the desired orientation of the drilling string (25). The drilling string
communication system
(378) then recalls from its system memory the desired orientation of the
drilling string (25) and
transmits data pertallllllg to the desired orientation to the device (20) on
the communications
bus.
The device (20) receives the data, clears the request flag and begins
actuating the
deflection assembly of the device (20) to actuate the device (20) to reflect
the desired
orientation of the drilling string (25). In the mean time the drilling string
communication
system (378) now requests orientation data only from the device (20) instead
of the drilling
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CA 02569070 2006-12-15
string orientation sensor apparatus (376) and transmits this orientation data
to the surface. The
drilling string ColI11n11111Cat10I1 SYStell'1 (378) will transmit drilling
string orientation sensor (376)
data when the speed of rotation is below the threshold speed and device
orientation data when
the speed of rotation is above the set threshold speed.
In event 3, the CANCEL time-out expires. If rotation of the drilling string
(25)
does not COII1111eI1Ce before the CANCEL command is expired then the device
(20) ceases to
recognize any commands again until the circulation flag goes to false (thus
indicating that
circulation above the tlu-eshold level has ceased). In this instance the
device (20) remains
actuated at its cun-ent actuation orientation if rotation later commences. If
the Deflection OFF
mode is this current actuation then the device (20) will continue in
Deflection OFF mode. If
the Deflection ON mode was engaged then device will continue at its previous
actuation
onentatlon.
In event 4, the circulation status goes back to false (thus indicating that
circulation above the tlu-eshold value has ceased). In this case the device
(20) returns to waiting
for a mode command state and is essentially reset back to initial conditions
and is waiting for a
command to tell it what to do next.
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