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US 11,306,536 B2Granted
Downhole motor assemblies, systems and methods
AssigneePhoenix Drill Tools, Inc.
InventorsBrock Bennion, Kyle Evans
Life of this patent
Estimating the term…
Abstract
The present disclosure is directed to improved downhole motor designs. In one illustrative embodiment, primary and secondary thrust bearings that are maintained in position by other structural components of the motor without compressive loading of the entire bearing assembly are positioned inside the motor housing for protection from cuttings and debris in the drilling fluid. In some illustrative embodiments, a drive train that features at least one multi-part sectional flex joint may allow for a shortened flex shaft while sufficiently converting eccentric forces from the power source to rotation of the mandrel.
Claims20
A drive unit for a downhole motor, comprising:
- a connection shaft;
- at least a first multi-part sectional constant velocity joint with increased flexibility attached to a first end of the connection shaft, wherein the multi-part sectional constant velocity joint comprises:
- at least a first top member having a longitudinal bore, an upper attachment section for attachment to the first end of the connection shaft, and a lower interlocking portion;
- at least a first middle member having a longitudinal bore, an upper interlocking portion, and a lower interlocking portion;
- at least a first lower member having a longitudinal bore, an upper interlocking portion;
- and
- at least a first connection pin extending through the longitudinal bores of the top member, the at least first middle member, and the lower member to align and secure the members for use,
- wherein the lower interlocking portion of the at least first top member, the upper interlocking portion of the at least first middle member, the lower interlocking portion of the at least first middle member, and the upper interlocking portion of the at least first lower member each comprise a series of recesses and splines, such that the adjacent interlocking portions are inserted into one another to allow flexible movement while maintaining sufficient contact between the members that rotational powered drive can be applied through the multi-part sectional constant velocity joint;
- and
- a mandrel in operative connection with the at least first multi-part sectional constant velocity joint, such that when rotational force is applied to the connection shaft, the rotational force is transmitted to the mandrel.
7 more elements
A drive assembly for a downhole motor, comprising:
- a drive shaft;
- at least a first multi-part sectional constant velocity joint with increased flexibility attached to a first end of the drive shaft;
- a mandrel attached to the at least first multi-part sectional constant velocity joint;
- a housing;
- a primary thrust bearing assembly disposed between the housing and the mandrel at a first position, the primary thrust bearing assembly comprising a lower primary thrust bearing element, an upper primary thrust bearing element, and a primary thrust bearing spring residing in a primary thrust bearing spring recess to urge the upper primary thrust bearing element downwards to contact the lower primary thrust bearing element, wherein the primary thrust bearing spring expands or contracts in response to mandrel movement between the on-bottom and off-bottom positions during use;
- and
- a secondary thrust bearing assembly disposed between the housing and the mandrel at a second position, wherein the primary thrust bearing assembly and the secondary thrust bearing assembly are maintained in position by other structural components of the motor without compressive loading that prevents longitudinal movement of the mandrel.
4 more elements
A downhole motor, comprising:
- a housing;
- a mandrel;
- a primary thrust bearing assembly disposed between the housing and the mandrel at a first position, the primary thrust bearing assembly comprising a lower primary thrust bearing element, an upper primary thrust bearing element, and a primary thrust bearing spring residing in a primary thrust bearing spring recess to urge the upper primary thrust bearing element downwards to contact the lower primary thrust bearing element, such that the primary thrust bearing assembly is maintained in position by the primary thrust bearing spring expanding or contracting in response to longitudinal mandrel movement;
- and
- a secondary thrust bearing assembly disposed between the housing and the mandrel at a second position, the secondary thrust bearing assembly comprising an upper secondary thrust bearing element, a lower secondary thrust bearing element, and a secondary thrust bearing spring residing in a secondary thrust bearing spring recess to urge the lower secondary thrust bearing element upwards to contact the upper secondary thrust bearing element, such that the secondary thrust bearing is maintained in position by the secondary bearing spring expanding or contracting in response to longitudinal mandrel movement.
2 more elements
Dependencies are inferred from the claim text.