# US 2019/0169948 A1 · Downhole tool actuators and indexing mechanisms > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2019/0169948 A1 - Document ID: US20190169948A1 - Status: Published application - Kind: A1 - Application number: 16/271,515 - Filed: 2019-02-08 - Published: 2019-06-06 - Earliest claimed: 2017-04-14 - Assignees: Turbo Drill Industries, Inc. - Applicants: Turbo Drill Industries, Inc. - Inventors: Mark ADAM - Web page: https://patentgrep.com/patent/US20190169948A1 ## CPC - E21B 23/00: Apparatus for displacing, setting, locking, releasing or removing tools, packers or the like in boreholes or wells (setting of casings, screens or liners E21B43/10) - E21B 23/004: {Indexing systems for guiding relative movement between telescoping parts of downhole tools} - E21B 23/006: {"J-slot" systems, i.e. lug and slot indexing mechanisms} - E21B 34/14: operated by movement of tools, e.g. sleeve valves operated by pistons or wire line tools {(E21B34/066 takes precedence)} - E21B 17/1014: {Flexible or expansible centering means, e.g. with pistons pressing against the wall of the well (E21B17/1042 takes precedence)} - E21B 2200/06: Sleeve valves - E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS ## Abstract A downhole tool control apparatus includes a control assembly, a stroking assembly, and a pocket sleeve positioned in an outer sub. The control assembly and stroking assembly are independently slidable axially within the outer sub. The control assembly and stroking assembly slide depending on the flow rate of fluid through the downhole tool actuator. The stroking assembly includes a spline barrel having a spline projection positioned within a spline pocket formed in the pocket sleeve. The pocket sleeve and control assembly include one or more ratchet teeth positioned in the pocket sleeve such that as the flow rate is changed between a high and a low flow rate, the spline projection engages the ratchet teeth until an actuated cycle is completed, allowing the downhole tool actuator to move to an actuation position. ## Claims ### Claim 1 A method for controlling a downhole tool using a downhole tool controller that is operatively coupled to the downhole tool, comprising at least the steps of: a) configuring the downhole tool controller in a first position by increasing a fluid flow through the downhole tool controller to a first high flow rate; b) configuring the downhole tool controller in a second position by lowering the fluid flow through the downhole tool controller from the first high flow rate to a first low flow rate; c) configuring the downhole tool controller in a third position by increasing the fluid flow through the downhole tool controller from the first low flow rate to a second high flow rate; and d) optionally, configuring the downhole tool controller in a fourth position by stopping fluid flow through the downhole tool actuator. ### Claim 2 (depends on 1) The method of claim 1, further including repeating steps a) and b) at least once before step d). ### Claim 3 (depends on 2) The method of claim 2, further including repeating step b) after step c) and then repeating step c) before step d). ### Claim 4 (depends on 1) The method of claim 1 wherein the downhole tool controller includes a control apparatus that defines a fluid flow path having a variable total flow area, wherein the control apparatus includes a control pin and a control piston that define the total flow area therebetween, and wherein the total flow area can be varied by moving the control piston relative to the control pin. ### Claim 5 (depends on 4) The method of claim 4 wherein the control apparatus has a control reset position in which the control piston and the control pin define a reset total flow area, a control low flow position in which the control piston and the control pin define a control total flow area, and a control high flow position in which the control piston and the control pin define a high flow total flow area, wherein the reset total flow area is less than the control total flow area and the control total flow area is less than the high flow total flow area, and wherein the control piston is biased into the control reset position. ### Claim 6 (depends on 5) The method of claim 5 wherein step a) includes generating a pressure differential across the control piston sufficient to shift the control apparatus to the control high flow position. ### Claim 7 (depends on 5) The method of claim 5 wherein step b) includes generating a control pressure differential across the control piston so as to shift the control apparatus to the control low flow position. ### Claim 8 (depends on 5) The method of claim 5 wherein step d) includes allowing the control piston to return to the control reset position. ### Claim 9 (depends on 3) The method of claim 3 wherein the downhole tool actuator includes a stroking assembly comprising: a stroking mandrel; a spline barrel, the spline barrel including a spline projection extending radially outward therefrom, the spline barrel coupled to the stroking mandrel such that the spline barrel is rotatable relative to the stroking mandrel; and a pocket assembly defining a spline pocket, wherein the spline projection is positioned within the spline pocket; and wherein the spline pocket includes a lower boundary, an upper boundary, a reset boundary, and an exit boundary, the upper boundary including a reset slope, the lower boundary including at least one high-flow ratchet tooth. ### Claim 10 (depends on 9) The method of claim 9 wherein the lower boundary of the spline pocket further includes an actuation slot that allows longitudinal movement of the spline projection the beyond the high flow ratchet tooth and wherein step c) includes moving the spline projection into the actuation slot. ### Claim 11 (depends on 10) The method of claim 10 wherein the lower boundary of the spline pocket further includes an actuation slot that allows longitudinal movement of the spline projection the beyond the high flow ratchet tooth and wherein steps a) through d) are carried out without moving the spline projection into the actuation slot. ### Claim 12 (depends on 10) The method of claim 10 wherein step c) includes: generating a control pressure differential across the control piston so as to exert a force on the control piston and shift the control assembly to a control high flow rate position; generating a stroking pressure differential between the stroking chamber and the stroking reaction chamber so as to exert a force on the stroking piston with the stroking pressure differential and shift the stroking assembly to an actuation position; and engaging the actuation slot with the spline projection. ### Claim 13 (depends on 10) The method of claim 10 wherein increasing the fluid flow rate to the second high flow rate causes the stroking assembly to move such that the spline projection engages either a high flow ratchet tooth or the actuation slot. ### Claim 14 (depends on 9) The method of claim 9 wherein the stroking mandrel includes a stroking piston and wherein step a) includes: generating a stroking pressure differential across the stroking piston so as to exert a force on the stroking piston and shift the stroking assembly to a high flow ratchet position and engaging the high flow ratchet tooth with the spline projection. ### Claim 15 (depends on 9) The method of claim 9 wherein step d) includes engaging the reset slope with the spline projection. ### Claim 16 (depends on 9) The method of claim 9 wherein the control apparatus further includes a low flow ratchet sleeve mechanically coupled to the control piston and including one or more low flow ratchet teeth, the low flow ratchet sleeve being longitudinally movable relative to the pocket assembly between a reset position in which the low flow ratchet sleeve cannot engage the spline projection and a low flow ratchet position in which the low flow ratchet sleeve can engage the spline projection. ### Claim 17 (depends on 16) The method of claim 16 wherein the low flow ratchet sleeve in the low flow ratchet position prevents the spline projection from contacting the reset slope or prevents upward movement of the spline projection along the reset slope and wherein step b) includes contacting the low flow ratchet sleeve with the spline projection. ### Claim 18 (depends on 16) The method of claim 16 wherein step d) includes moving the low flow ratchet sleeve to the reset position. ### Claim 19 (depends on 16) The method of claim 16 wherein a reduction in the fluid flow rate may cause the stroking assembly to move such that the spline projection engages either a low flow ratchet tooth or the reset slope. ### Claim 20 A downhole tool control apparatus comprising: an outer sub, the outer sub being tubular, the outer sub having an inner surface defining a control apparatus bore; a control assembly having an inner profile that includes first and second control sleeve diameters, the control assembly being longitudinally moveable relative to the outer sub; a control pin positioned within the control apparatus bore and mechanically coupled to the outer sub and having a pin outer profile, wherein the pin outer profile includes first and second pin diameters; a stroking assembly, the stroking assembly positioned within the control apparatus bore, the stroking assembly including: a spline barrel having a spline projection, the spline barrel being rotatable and axially moveable relative to the outer sub; and a spline pocket positioned to engage the spline projection of the stroking assembly; wherein a flow path is defined between the control pin and the control assembly, the flow path having a total flow area, and wherein the total flow area is can be changed by moving the control assembly relative to the control pin. ### Claim 21 (depends on 20) The apparatus of claim 20 wherein the first pin diameter is smaller than the second pin diameter and the first control sleeve diameter is smaller than the second control sleeve diameter. ### Claim 22 (depends on 21) The apparatus of claim 21 wherein the second pin diameter is smaller than the first control sleeve diameter. ### Claim 23 (depends on 20) The apparatus of claim 20 wherein the control assembly is biased toward the control pin. ### Claim 24 (depends on 21) The apparatus of claim 21 wherein the control assembly is can be positioned relative to the control pin so as to define a reset total flow area, a control total flow area, or a high flow total flow area, wherein the reset total flow area is smaller than the high flow total flow area. ### Claim 25 (depends on 24) The apparatus of claim 24 wherein the control assembly is biased toward the reset total flow area position. ### Claim 26 (depends on 20) The apparatus of claim 20 wherein the spline pocket includes a lower boundary, an upper boundary, a reset boundary, and an exit boundary, the lower boundary including a reset slope, the upper boundary including at least one high-flow ratchet tooth. ### Claim 27 (depends on 20) The apparatus of claim 20 wherein the stroking assembly is biased toward the control assembly. ### Claim 28 (depends on 20) The apparatus of claim 20, further including a low flow ratchet sleeve mechanically coupled to the control assembly and including one or more low flow ratchet teeth.