US20150369283A1 - Bearing assemblies and bearing apparatuses - Google Patents
Bearing assemblies and bearing apparatuses Download PDFInfo
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- US20150369283A1 US20150369283A1 US14/839,328 US201514839328A US2015369283A1 US 20150369283 A1 US20150369283 A1 US 20150369283A1 US 201514839328 A US201514839328 A US 201514839328A US 2015369283 A1 US2015369283 A1 US 2015369283A1
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- bearing
- circumferentially
- spaced
- elements
- bearing elements
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
- F16C33/02—Parts of sliding-contact bearings
- F16C33/04—Brasses; Bushes; Linings
- F16C33/06—Sliding surface mainly made of metal
- F16C33/10—Construction relative to lubrication
- F16C33/1025—Construction relative to lubrication with liquid, e.g. oil, as lubricant
- F16C33/106—Details of distribution or circulation inside the bearings, e.g. details of the bearing surfaces to affect flow or pressure of the liquid
- F16C33/108—Details of distribution or circulation inside the bearings, e.g. details of the bearing surfaces to affect flow or pressure of the liquid with a plurality of elements forming the bearing surfaces, e.g. bearing pads
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B4/00—Drives for drilling, used in the borehole
- E21B4/003—Bearing, sealing, lubricating details
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- F16C17/00—Sliding-contact bearings for exclusively rotary movement
- F16C17/02—Sliding-contact bearings for exclusively rotary movement for radial load only
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- F16C17/00—Sliding-contact bearings for exclusively rotary movement
- F16C17/04—Sliding-contact bearings for exclusively rotary movement for axial load only
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
- F16C33/02—Parts of sliding-contact bearings
- F16C33/04—Brasses; Bushes; Linings
- F16C33/043—Sliding surface consisting mainly of ceramics, cermets or hard carbon, e.g. diamond like carbon [DLC]
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
- F16C33/02—Parts of sliding-contact bearings
- F16C33/04—Brasses; Bushes; Linings
- F16C33/26—Brasses; Bushes; Linings made from wire coils; made from a number of discs, rings, rods, or other members
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- F16C2352/00—Apparatus for drilling
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- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Geology (AREA)
- Mining & Mineral Resources (AREA)
- Life Sciences & Earth Sciences (AREA)
- Chemical & Material Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Fluid Mechanics (AREA)
- Environmental & Geological Engineering (AREA)
- Physics & Mathematics (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Ceramic Engineering (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Rolling Contact Bearings (AREA)
- Sliding-Contact Bearings (AREA)
- Earth Drilling (AREA)
- Shafts, Cranks, Connecting Bars, And Related Bearings (AREA)
- Support Of The Bearing (AREA)
Abstract
In an embodiment, a bearing apparatus comprises a first bearing assembly including a plurality of circumferentially-spaced first bearing elements each of which includes a first bearing surface. The bearing apparatus further includes a second bearing assembly including a plurality of circumferentially-spaced second bearing elements each of which includes a second bearing surface oriented to engage the first bearing surfaces of the first bearing assembly during operation. At least one of the second bearing elements may be circumferentially spaced from an adjacent one of the second bearing elements by a lateral spacing greater than a lateral dimension of the at least one of the second bearing elements.
Description
- This application is a continuation of U.S. application Ser. No. 14/079,218 filed on 13 Nov. 2013, which is a continuation of U.S. application Ser. No. 13/599,752 filed on 30 Aug. 2012 (now U.S. Pat. No. 8,616,770 issued on 31 Dec. 2013), which is a continuation of U.S. application Ser. No. 12/394,489 filed on 27 Feb. 2009 (now U.S. Pat. No. 8,277,124 issued on 2 Oct. 2012). The disclosure of each of foregoing applications is incorporated, in its entirety, by this reference.
- Subterranean drilling systems that employ downhole drilling motors are commonly used for drilling boreholes in the earth for oil and gas exploration.
FIG. 1 is a schematic isometric cutaway view of a prior artsubterranean drilling system 100. Thesubterranean drilling system 100 includes ahousing 102 enclosing adownhole drilling motor 104 that is operably connected to anoutput shaft 106. A thrust-bearingapparatus 108 is also operably coupled to thedownhole drilling motor 104. Arotary drill bit 112 configured to engage a subterranean formation and drill a borehole is connected to theoutput shaft 106. Therotary drill bit 112 is shown as a roller-cone bit including a plurality ofroller cones 114. As the borehole is drilled, pipe sections may be connected to thesubterranean drilling system 100 to form a drill string capable of progressively drilling the borehole to a greater depth within the earth. - The thrust-bearing
apparatus 108 includes astator 116 that does not rotate and arotor 118 that is attached to theoutput shaft 106 and rotates with theoutput shaft 106. Thestator 116 androtor 118 each include a plurality ofbearing elements 120 that may be fabricated from polycrystalline diamond compacts (“PDCs”) that provide diamond bearing surfaces that bear against each other during use. - In operation, high-pressure drilling fluid is circulated through the drill string and power section (not shown) of the
downhole drilling motor 104, usually prior to therotary drill bit 112 engaging the bottom of the borehole, to generate torque and rotate theoutput shaft 106 and therotary drill bit 112 attached to theoutput shaft 106. When therotary drill bit 112 engages the bottom of the borehole, a thrust load is generated, which is commonly referred to as “on-bottom thrust” that tends to compress the thrust-bearingapparatus 108. The on-bottom thrust is carried, at least in part, by the thrust-bearingapparatus 108. Fluid flow through the power section may cause what is commonly referred to as “off-bottom thrust,” which is carried, at least in part, by another thrust-bearing apparatus that is not shown inFIG. 1 . The drilling fluid used to generate the torque for rotating therotary drill bit 112 exits openings formed in therotary drill bit 112 and returns to the surface, carrying cuttings of the subterranean formation through an annular space between the drilled borehole and thesubterranean drilling system 100. Typically, a portion of the drilling fluid is diverted by thedownhole drilling motor 104 to cool and lubricate the bearingelements 120 of the thrust-bearingapparatus 108. - The off-bottom and on-bottom thrust carried by the thrust-bearing apparatuses can be extremely large. The operational lifetime of the thrust-bearing apparatuses often determines the useful life of the
subterranean drilling system 100. Therefore, manufacturers and users of subterranean drilling systems continue to seek improved bearing apparatuses. - Embodiments of the invention are directed to bearing apparatuses comprising a bearing assembly including bearing elements, with at least one bearing element spaced from an adjacent bearing element by a lateral spacing greater than a lateral dimension of the at least one bearing element. The disclosed bearing apparatuses may be used in a number of applications, such as downhole motors in subterranean drilling systems or directional drilling systems, roller-cone drill bits, and many other applications.
- In an embodiment, a bearing apparatus comprises a first bearing assembly including a plurality of circumferentially-spaced first bearing elements each of which includes a first bearing surface. The bearing apparatus further includes a second bearing assembly including a plurality of circumferentially-spaced second bearing elements each of which includes a second bearing surface oriented to engage the first bearing surfaces of the first bearing assembly during operation. At least one of the second bearing elements may be circumferentially spaced from an adjacent one of the second bearing elements by a lateral spacing greater than a lateral dimension of the at least one of the second bearing elements.
- Other embodiments include downhole motors for use in drilling systems that may utilize any of the disclosed bearing apparatuses.
- The drawings illustrate several embodiments of the invention, wherein identical reference numerals refer to identical elements or features in different views or embodiments shown in the drawings.
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FIG. 1 is a schematic isometric cutaway view of a prior art subterranean drilling system including at least one thrust-bearing apparatus. -
FIG. 2A is an isometric cutaway view of a thrust-bearing apparatus according to an embodiment of the invention. -
FIG. 2B is an isometric view of the first bearing assembly shown inFIG. 2A . -
FIG. 2C is an isometric view of the second bearing assembly shown inFIG. 2A . -
FIG. 2D is a partial cross-sectional view of the second bearing assembly shown inFIG. 2C that details a bearing element and a flow obstruction element thereof. -
FIG. 3A is an isometric view of a radial bearing apparatus according to an embodiment of the invention. -
FIG. 3B is an isometric view of the inner race shown inFIG. 3A . -
FIG. 3C is an isometric view of the outer race shown inFIG. 3A . -
FIG. 3D is a partial cross-sectional view of the outer race that details a bearing element and a flow obstruction element thereof. -
FIG. 4 is a side cross-sectional view of an embodiment of a bearing element suitable for use in any of the bearing assemblies disclosed herein. -
FIG. 5 is a schematic isometric cutaway view of an embodiment of a subterranean drilling system that includes at least one of the thrust-bearing apparatuses shown inFIG. 2A . - Embodiments of the invention are directed to bearing apparatuses comprising a bearing assembly including bearing elements, with at least one bearing element spaced from an adjacent bearing element by a lateral spacing greater than a lateral dimension of the at least one bearing element. The disclosed bearing apparatuses may be used in a number of applications, such as downhole motors in subterranean drilling systems or directional drilling systems, roller-cone drill bits, and many other applications.
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FIG. 2A is an isometric cutaway view of a thrust-bearingapparatus 200, suitable for use in a subterranean drilling system, according to an embodiment of the invention. The thrust-bearingapparatus 200 includes afirst bearing assembly 202 and asecond bearing assembly 204. One of thefirst bearing assembly 202 or thesecond bearing assembly 204 may serve as a rotor and the other one of thefirst bearing assembly 202 or thesecond bearing assembly 204 may serve as a stator in the thrust-bearingapparatus 200. One or both of thefirst bearing assembly 202 and thesecond bearing assembly 204 may rotate about a thrust axis 206 (FIG. 2B ) along which thrust may be generally directed during use. -
FIG. 2B is an isometric view of thefirst bearing assembly 202 shown inFIG. 2A . Thefirst bearing assembly 202 includes a firstbearing support ring 208 defining anaperture 210 through which a shaft of, for example, a downhole drilling motor may pass. The firstbearing support ring 208 may comprise a metallic material (e.g., steel) or a more wear-resistant material, such as cemented tungsten carbide, silicon carbide, or another more wear-resistant material. The firstbearing support ring 208 includes a plurality of circumferentially-spaced first bearingelements 212 mounted thereto and distributed about the thrust axis 206 (FIG. 2B ). For example, thefirst bearing elements 212 may be mounted to the firstbearing support ring 208 by brazing or press-fitting, via one or more fasteners, or another suitable technique. Each of thefirst bearing elements 212 includes abearing surface 214. Thefirst bearing elements 212 exhibit an average first lateral dimension (e.g., an average diameter) that may be determined by taking the average of the respective maximum lateral dimensions of eachfirst bearing element 212. At least onefirst bearing element 212 may be separated from an adjacentfirst bearing element 212 by a respective firstlateral spacing 218 that is less than a lateral dimension 216 (e.g., a diameter) of the at least onefirst bearing element 212. The firstlateral spacing 218 may be measured as a linear distance between adjacentfirst bearing elements 212 or an arc length between adjacentfirst bearing elements 212 based on a reference circle that extends about thethrust axis 206. In an embodiment, a portion of thefirst bearing elements 212 or eachfirst bearing element 212 may be separated from an adjacentfirst bearing element 212 by a respective lateral spacing 218 that is less than the average first lateral dimension of thefirst bearing elements 212. - In some embodiments, the
first bearing elements 212 may be substantially equally circumferentially spaced from each other, with the respective firstlateral spacing 218 between adjacentfirst bearing elements 212 being approximately the same. However, in other embodiments, thefirst bearing elements 212 may be non-uniformly circumferentially spaced from each other. -
FIG. 2C is an isometric view of thesecond bearing assembly 204 shown inFIG. 2A . Thesecond bearing assembly 204 includes a secondbearing support ring 220 defining anaperture 222 through which the shaft of, for example, the downhole drilling motor may pass. The secondbearing support ring 220 may be made from the same or similar materials as the first bearing support ring 208 (FIGS. 2A and 2B ). The secondbearing support ring 220 includes a plurality of circumferentially-spaced second bearingelements 224 mounted thereto using any of the previously mentioned mounting techniques. Thesecond bearing elements 224 are distributed about the thrust axis 206 (FIG. 2B ). The number ofsecond bearing elements 224 may be substantially less than the number of first bearing elements 212 (FIG. 2B ). For example, thefirst bearing assembly 202 may include more than two to four times (e.g., three times) the number of bearing elements included in thesecond bearing assembly 204. As merely a non-limiting embodiment, thefirst bearing assembly 202 may include nineteen of thefirst bearing elements 212 and thesecond bearing assembly 204 may include six of thesecond bearing elements 224. Eachsecond bearing element 224 includes abearing surface 226 that opposes and bears against one or more of the bearing surfaces 214 (FIG. 2B ) during use. - Still referring to
FIG. 2C , thesecond bearing elements 224 exhibit an average second lateral dimension (e.g., an average diameter) that may be determined by taking the average of the respective maximum lateral dimensions of eachsecond bearing element 224. At least onesecond bearing element 224 may be separated from an adjacentsecond bearing element 224 by a respective second lateral spacing 230 that is greater than a second lateral dimension 228 (e.g., a diameter) of the at least onesecond bearing element 224. The second lateral spacing 230 may be measured as a linear distance between adjacentsecond bearing elements 224 or an arc length between adjacentsecond bearing elements 224 based on a reference circle that extends about thethrust axis 206. In an embodiment, a portion of thesecond bearing elements 224 or eachsecond bearing element 224 may be separated from an adjacentsecond bearing element 224 by a respective lateral spacing 230 that is less than the average second lateral dimension of thesecond bearing elements 224. In an embodiment, the second lateral spacing 230 may be at least about two times (e.g., about two to about four times) the average second lateral dimension. The secondlateral dimension 228 of eachsecond bearing element 224 may be equal to or greater than the first lateral spacing 218 (FIG. 2B ) between adjacent first bearing elements 212 (FIG. 2B ) to prevent the first andsecond bearing assemblies - In some embodiments, the
second bearing elements 224 may be substantially equally circumferentially spaced from each other, with the respective second lateral spacing 230 between adjacentsecond bearing elements 224 being approximately the same. However, in other embodiments, thesecond bearing elements 224 may be non-uniformly circumferentially spaced from each other. - During use, fluid (e.g., drilling mud) is pumped through a drill string of a subterranean drilling system to effect rotation of a drill bit (not shown). A portion of the fluid may also be permitted to flow around and/or over the
first bearing elements 212 andsecond bearing elements 224 of the first andsecond bearing assemblies FIG. 2C and the partial cross-sectional view ofFIG. 2D , in some embodiments, in order to enhance the flow rate around and over the first bearing elements 212 (FIG. 2B ) and thesecond bearing elements 224, at least one flow obstruction element may be provided. For example, a plurality offlow obstruction elements 232 may be provided, with eachflow obstruction element 232 positioned between adjacentsecond bearing elements 224. Eachflow obstruction element 232 may have alateral dimension 234 such that they occupy a major portion of the linear or arcuate distance between the adjacentsecond bearing elements 224. For example, in the illustrated embodiment, theflow obstruction elements 232 occupy the distance between adjacent bearingelements 224 such that a minimumlateral dimension 236 of a gap between aflow obstruction element 232 and an adjacentsecond bearing element 224 is less than the average second lateral dimension of thesecond bearing elements 224. In the illustrated embodiment, theflow obstruction elements 232 have an arcuate shape and may be integrally formed as part of the secondbearing support ring 220. However, theflow obstruction elements 232 may be removable, replaceable, or may have other configurations that depart from the illustrated configuration. - Referring specifically to
FIG. 2D , theflow obstruction elements 232 may have aterminal surface 238 that is positioned below the bearing surfaces 226 of thesecond bearing elements 224 by adistance 240. Thedistance 240 may be chosen to be greater than the expected wear of thesecond bearing elements 224 so that the terminal surfaces 238 (shown inFIGS. 2C and 2D ) of theflow obstruction elements 232 do not contact thefirst bearing elements 212 during use. More particularly, each flowobstruction element 232 may be configured so that fluid flow between adjacentsecond bearing elements 224 may exhibit an average Reynolds number of about 10,000 to about 60,000 (e.g., about 45,000 to about 60,000) during use. In an embodiment, thedistance 240 may be about 0.0050 inches to about 0.030 inches and, more particularly, about 0.010 inches. - As an alternative to or in addition to the
flow obstruction elements 232 being employed on thesecond bearing assembly 204, in another embodiment, flow obstruction elements may also be employed on thefirst bearing assembly 202 between thefirst bearing elements 212 thereof. -
FIG. 3A is an isometric view of aradial bearing apparatus 300, suitable for use in a subterranean drilling system, according to an embodiment of the invention. Theradial bearing apparatus 300 includes aninner race 302 received by anouter race 304. One of theinner race 302 or theouter race 304 may serve as a rotor and the other one of theinner race 302 or theouter race 304 may serve as a stator in theradial bearing apparatus 300. One or both of theinner race 302 and theouter race 304 rotate about arotation axis 306 during use. -
FIG. 3B is an isometric view of theinner race 302 shown inFIG. 3A . Theinner race 302 includes a firstbearing support ring 308 defining anaperture 310 through which a shaft or a spindle may be inserted. The firstbearing support ring 308 may be made from the same or similar materials as the first bearing support ring 208 (FIGS. 2A and 2B ). The firstbearing support ring 308 includes a plurality of circumferentially-spaced first bearingelements 312 mounted thereto using any of the previously mentioned mounting techniques. Thefirst bearing elements 312 are distributed about therotation axis 306. Eachfirst bearing element 312 includes a convexly-curved bearing surface 314 oriented in a radially outward direction. Thefirst bearing elements 312 exhibit an average first lateral dimension that may be determined by taking the average of the respective maximum lateral dimensions of eachfirst bearing element 312. At least onefirst bearing element 312 may be separated from an adjacentfirst bearing element 312 by a respective lateral spacing 318 that is less than a first lateral dimension (e.g., a diameter) 316 of the at least onefirst bearing element 312 and may be measured as an arc length between adjacentfirst bearing elements 312 based on a reference circle that extends about therotation axis 306. In an embodiment, a portion of or eachfirst bearing element 312 may be separated from an adjacentfirst bearing element 312 by a respective lateral spacing 318 that is less than the average first lateral dimension of thefirst bearing elements 312. Thefirst bearing elements 312 may be substantially equally circumferentially spaced or non-uniformly spaced about therotation axis 306. -
FIG. 3C is an isometric view of theouter race 304 shown inFIG. 3A . Theouter race 304 includes a secondbearing support ring 320 having a plurality of circumferentially-spaced second bearingelements 322 mounted thereto using any of the previously mentioned mounting techniques. The secondbearing support ring 320 may be made from the same or similar materials as the first bearing support ring 208 (FIGS. 2A and 2B ). Thesecond bearing elements 322 are distributed about therotation axis 306. Eachsecond bearing element 322 includes a concavely-curved bearing surface 324 that corresponds to the curvature of the convexly-curved bearing surfaces 314 of thefirst bearing elements 312 and is oriented in a radially inward direction. Thesecond bearing elements 322 exhibit an average lateral dimension that may be determined by taking the average of the respective maximum lateral dimensions of eachsecond bearing element 322. - Still referring to
FIG. 3C , at least onesecond bearing element 322 may be separated from an adjacentsecond bearing element 322 by a respective lateral spacing 328 that is greater than a secondlateral dimension 326 of the at least onesecond bearing element 322 and may be measured as an arc length based on a reference circle that extends about therotation axis 306. In an embodiment, a portion of or eachsecond bearing element 322 may be separated from an adjacentsecond bearing element 322 by a respective lateral spacing 328 that is greater than the average second lateral dimension of thesecond bearing elements 322. In an embodiment, thelateral spacing 328 may be at least about two times (e.g., about two to about four times) the average lateral dimension of thesecond bearing elements 322. The average lateral dimension of thesecond bearing elements 322 may be equal to or greater than thelateral spacing 318 between adjacentfirst bearing elements 312 to prevent interlocking of theinner race 302 and theouter race 304 during use. The number ofsecond bearing elements 322 may be substantially less than the number offirst bearing elements 312. For example, thefirst bearing assembly 302 may include more than two to four times (e.g., three times) the number of bearing elements included in thesecond bearing assembly 304. As merely a non-limiting embodiment, theinner race 302 may include nineteen of thefirst bearing elements 312 and theouter race 304 may include six of thesecond bearing elements 322. - In an embodiment, the
second bearing elements 322 are substantially equally circumferentially spaced about therotation axis 306. However, in other embodiments, thesecond bearing elements 322 may be circumferentially non-uniformly spaced about therotation axis 306. - During use, the bearing surfaces 314 of the
first bearing elements 312 slidingly engage bearingsurfaces 324 of thesecond bearing elements 322 as theinner race 302 rotates relative to theouter race 304. - During operation, fluid (e.g., drilling mud) may be pumped between the
inner race 302 and theouter race 304 to flow around and/or over thefirst bearing elements 312 andsecond bearing elements 322 for cooling and/or lubrication thereof. Referring to the illustrated embodiment shown inFIG. 3C and the partial cross-sectional view ofFIG. 3D , in some embodiments, in order to provide a selected flow rate around and/or over thefirst bearing elements 312 and thesecond bearing elements 322, a plurality offlow obstruction elements 330 may be provided. Eachflow obstruction element 330 is positioned between adjacentsecond bearing elements 322. Eachflow obstruction element 330 may exhibit a maximum lateral dimension orwidth 332 such that it occupies a major portion of the arcuate distance between adjacentsecond bearing elements 322. For example, in the illustrated embodiment, theflow obstruction elements 330 occupy the distance between adjacent bearingelements 322 such that anangular width 334 of a gap between aflow obstruction element 330 and an adjacentsecond bearing element 322 is less than the average lateral dimension of thesecond bearing elements 322. - As an alternative to or in addition to the
flow obstruction elements 330 being employed on thesecond bearing assembly 304, in another embodiment, flow obstruction elements may also be employed on thefirst bearing assembly 302 between thefirst bearing elements 312 thereof. - Still referring to
FIG. 3D , each flowobstruction element 330 may include a terminal surface 338 (shown inFIGS. 3C and 3D as curved) that is positioned below the bearing surfaces 324 of thesecond bearing elements 322 by adistance 340. Thedistance 340 may be chosen to be greater than the expected wear of thesecond bearing elements 322 so that theterminal surfaces 338 of theflow obstruction elements 330 do not contact thefirst bearing elements 312 during use. In an embodiment, thedistance 340 may be between 0.0050 inches and 0.030 inches and, more particularly, about 0.010 inches. - The
radial bearing apparatus 300 may be employed in a variety of mechanical applications. For example, a roller-cone rotary drill bit may employ theradial bearing apparatus 300. More specifically, theinner race 302 may be mounted to a spindle of a roller cone and theouter race 304 may be affixed to an inner bore formed within the roller cone, and theouter race 304 andinner race 302 may be assembled to form theradial bearing apparatus 300. Theradial bearing apparatus 300 may also be employed in a downhole drilling motor and turbine. - Referring to
FIG. 4 , a number of different types of bearing elements may be employed in the thrust-bearingapparatus 200 andradial bearing apparatus 300.FIG. 4 is a side cross-sectional view of an embodiment of abearing element 400 suitable for use in any of the bearing assemblies disclosed herein. Thebearing element 400 may be a superhard compact that includes a superhard table 402 of superhard material bonded to asubstrate 404. The superhard table 402 includes a suitably configured bearingsurface 406. For example, the bearing element may be PDC including a polycrystalline diamond table bonded to a cobalt-cemented tungsten carbide substrate. - The term “superhard,” as used herein, means a material having a hardness at least equal to a hardness of tungsten carbide. The superhard table 402 may comprise any suitable superhard material, such as silicon carbide, a diamond-silicon carbide composite, polycrystalline cubic boron nitride, polycrystalline cubic boron nitride and polycrystalline diamond, or any other suitable superhard material or combination of superhard materials.
- As noted hereinabove, there may be fewer
second bearing elements assembly 204 andouter race 304 than there are first bearingelements first bearing assembly 202 andinner race 302. In some embodiments, a portion of or all of thesecond bearing elements first bearing elements second bearing elements first bearing elements - A number of different types of thermally-stable PDCs may be used. In an embodiment, a thermally-stable PDC may include a cemented carbide substrate bonded to a polycrystalline diamond table. A portion of or substantially all of the metallic catalyst used to catalyze formation of the polycrystalline diamond table may be leached therefrom. Another suitable thermally-stable PDC includes an at least partially leached polycrystalline diamond table that is bonded to a cemented carbide substrate. Yet another suitable thermally-stable PDC includes a polycrystalline diamond table bonded to a cemented carbide substrate, with interstitial regions between bonded diamond grains of the polycrystalline diamond table having a nonmetallic catalyst disposed therein (e.g., one or more alkali metal carbonates, one or more alkaline metal carbonates, one or more alkaline earth metal hydroxides, or combinations thereof), silicon carbide, or combinations of the foregoing. As yet a further example, pre-sintered PCD tables may be bonded to a substrate (or employed separately) in various configurations, such as back-filled, leached, etc.
- The thermal stability of a PDC may be evaluated by measuring the distance cut in a granite workpiece prior to failure without using coolant in a vertical turret lathe (“VTL”) test. The distance cut is considered representative of the thermal stability of the PDC. In some embodiments, the
second bearing elements first bearing elements -
FIG. 5 is a schematic isometric cutaway view of asubterranean drilling system 500 that includes at least one of the thrust-bearingapparatuses 200 shown inFIG. 2A according to another embodiment. Thesubterranean drilling system 500 includes ahousing 502 enclosing a downhole drilling motor 504 (i.e., a motor, turbine, or any other device capable of rotating an output shaft) that is operably connected to anoutput shaft 506. A first thrust-bearing apparatus 200 1 (FIG. 2A ) is operably coupled to thedownhole drilling motor 504 to form a motor assembly. A second thrust-bearing apparatus 200 2 (FIG. 2A ) is operably coupled to theoutput shaft 506. Arotary drill bit 508 configured to engage a subterranean formation and drill a borehole is connected to theoutput shaft 506. Therotary drill bit 508 is shown as a roller-cone bit including a plurality ofroller cones 510. However, other embodiments may utilize different types of rotary drill bits, such as a fixed-cutter drill bit. As the borehole is drilled, pipe sections may be connected to thesubterranean drilling system 500 to form a drill string capable of progressively drilling the borehole to a greater depth within the earth. - The first thrust-bearing
apparatus 200 1 includes afirst bearing assembly 202 configured as a stator that does not rotate and asecond bearing assembly 204 configured as a rotor that is attached to theoutput shaft 506 and rotates with theoutput shaft 506. The on-bottom thrust generated when thedrill bit 508 engages the bottom of the borehole may be carried, at least in part, by the first thrust-bearingapparatus 200 1. The second thrust-bearingapparatus 200 2 includes afirst bearing assembly 202 configured as a stator that does not rotate and asecond bearing assembly 204 configured as a rotor that is attached to theoutput shaft 506 and rotates with theoutput shaft 506. Fluid flow through the power section of thedownhole drilling motor 504 may cause what is commonly referred to as “off-bottom thrust,” which may be carried, at least in part, by the second thrust-bearingapparatus 200 2. - During use, drilling fluid may be circulated through the
downhole drilling motor 504 to generate torque and effect rotation of theoutput shaft 506, and the second bearing assemblies 204 (i.e., the rotors) and therotary drill bit 508 attached thereto so that a borehole may be drilled. A portion of the drilling fluid may also be used to lubricate opposing bearing surfaces of the bearing elements of the thrust-bearingapparatuses elements 212 are illustrated inFIG. 5 . - While various aspects and embodiments have been disclosed herein, other aspects and embodiments are contemplated. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting. Additionally, the words “including,” “having,” and variants thereof (e.g., “includes” and “has”) as used herein, including the claims, shall have the same meaning as the word “comprising” and variants thereof (e.g., “comprise” and “comprises”).
Claims (25)
1. A bearing support ring for use in a bearing assembly of a bearing apparatus used in a subterranean drilling system, the bearing support ring comprising:
a support ring body defining a plurality of circumferentially-spaced recesses, each of the plurality of circumferentially-spaced recesses configured to receive a corresponding one of a plurality of superhard bearing elements; and
at least one flow obstruction element positioned and configured to inhibit fluid flow between the plurality of superhard bearing elements, the at least one flow obstruction element positioned circumferentially between circumferentially adjacent recesses of the plurality of circumferentially-spaced recesses, the at least one flow obstruction element including a terminal surface positioned below each bearing surface of the plurality of superhard bearing elements.
2. The bearing support ring of claim 1 , wherein each of the plurality of circumferentially-spaced recesses is circumferentially spaced from a circumferentially nearest one of the plurality of circumferentially-spaced recesses by a respective lateral spacing greater than a respective lateral dimension of the circumferentially nearest one of the plurality of circumferentially-spaced recesses.
3. The bearing support ring of claim 1 , wherein the plurality of circumferentially-spaced recesses are substantially equally circumferentially spaced from each other.
4. The bearing support ring of claim 1 , wherein the at least one flow obstruction element is laterally spaced a distance from a circumferentially adjacent recess of the plurality of circumferentially-spaced recesses less than an average lateral dimension of the plurality of circumferentially-spaced recesses.
5. The bearing support ring of claim 1 , wherein the at least one flow obstruction element is formed integrally with the support ring body.
6. The bearing support ring of claim 1 , wherein the terminal surface of the at least one flow obstruction element is positioned below each bearing surface of the plurality of superhard bearing elements by a distance of 0.0050 inches to 0.030 inches.
7. The bearing support ring of claim 1 , wherein a circumferential gap between the at least one flow obstruction element and an adjacent recess is less than an average lateral dimension of the recess.
8. The bearing support ring of claim 1 , wherein the support ring body includes at least one of tungsten carbide or silicon carbide.
9. The bearing support ring of claim 1 , wherein the at least one flow obstruction element includes a plurality of flow obstruction elements, each of the plurality of flow obstruction elements positioned circumferentially between circumferentially adjacent recesses of the plurality of circumferentially-spaced recesses.
10. A bearing apparatus, comprising:
a first bearing assembly including:
a plurality of circumferentially-spaced first bearing elements, each of the plurality of circumferentially-spaced first bearing element includes a first bearing surface including a first material, each of the plurality of circumferentially-spaced first bearing elements circumferentially spaced from a circumferentially nearest one of the plurality of circumferentially-spaced first bearing elements by a respective first lateral spacing; and
a second bearing assembly including:
a bearing support ring;
a plurality of circumferentially-spaced second bearing elements fixed to the bearing support ring, each of the plurality of circumferentially-spaced second bearing elements including a second bearing surface, the second bearing surface including a second material that is different from the first material; and
wherein each of the plurality of circumferentially-spaced second bearing elements is circumferentially spaced from a circumferentially nearest one of the plurality of circumferentially-spaced second bearing elements by a respective second lateral spacing greater than a respective second lateral dimension of the circumferentially nearest one of the plurality of circumferentially-spaced second bearing elements, the second lateral spacing greater than the first lateral spacing.
11. The bearing apparatus of claim 10 , wherein at least one of the first material or the second material includes a superhard material.
12. The bearing apparatus of claim 10 , wherein the first material includes at least one of silicon carbide, diamond-silicon carbide composite, polycrystalline cubic boron nitride, or polycrystalline cubic boron nitride and polycrystalline diamond; and the second material includes polycrystalline diamond.
13. The bearing apparatus of claim 10 , wherein at least some of the plurality of circumferentially-spaced second bearing elements are more thermally stable than the plurality of circumferentially-spaced first bearing elements.
14. The bearing apparatus of claim 13 , wherein the more thermally-stable bearing elements include at least partially leached polycrystalline diamond.
15. The bearing apparatus of claim 10 , wherein the plurality of circumferentially-spaced second bearing elements are attached to the bearing support ring by at least one of brazing or press-fitting.
16. The bearing apparatus of claim 10 , wherein the first lateral spacing is less than a respective first lateral dimension of the circumferentially nearest one of the plurality of circumferentially-spaced first bearing elements.
17. The bearing apparatus according to claim 10 , wherein the number of the plurality of circumferentially-spaced second bearing elements is less than the number of the plurality of circumferentially-spaced first bearing elements.
18. The bearing apparatus according to claim 10 , wherein the respective second lateral dimension is equal to or greater than the respective first lateral spacing.
19. A bearing apparatus, comprising:
a first bearing assembly including a plurality of circumferentially-spaced first bearing elements each of which includes a first bearing surface; and
a second bearing assembly including:
a bearing support ring having a plurality of circumferentially-spaced second bearing elements mounted thereto;
wherein each of the plurality of circumferentially-spaced second bearing elements includes a second bearing surface oriented to engage the first bearing surfaces of the first bearing assembly during operation; and
wherein the bearing support ring includes at least one flow obstruction element positioned circumferentially between circumferentially adjacent second bearing elements of the plurality of circumferentially-spaced second bearing elements and includes a terminal surface positioned below each of the second bearing surfaces.
20. The bearing apparatus according to claim 19 , wherein each of the plurality of circumferentially-spaced second bearing elements is circumferentially spaced from a circumferentially nearest one of the plurality of circumferentially-spaced second bearing elements by a respective second lateral spacing greater than a respective second lateral dimension of the circumferentially nearest one of the plurality of circumferentially-spaced second bearing elements, the second lateral spacing greater than the first lateral spacing.
21. The bearing apparatus according to claim 20 , wherein the respective second lateral spacing is at least about two times greater than an average of the second lateral dimensions of the plurality of circumferentially-spaced second bearing elements.
22. The bearing apparatus according to claim 19 , wherein the at least one flow obstruction element is laterally spaced a distance from a circumferentially adjacent second bearing element of the plurality of circumferentially-spaced second bearing elements less than an average lateral dimension of the plurality of circumferentially-spaced second bearing elements.
23. The bearing apparatus according to claim 19 , wherein the number of the second bearing elements is less than the number of the first bearing elements.
24. The bearing apparatus according to claim 19 , wherein the plurality of circumferentially-spaced first bearing elements and the plurality of circumferentially-spaced second bearing elements are distributed about a thrust axis; or wherein the first bearing surfaces of the plurality of circumferentially-spaced first bearing elements and the second bearing surfaces of the plurality of circumferentially-spaced second bearing elements are generally radially oriented.
25. The bearing apparatus according to claim 19 , wherein each of the first and second bearing surfaces includes polycrystalline diamond.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US14/839,328 US20150369283A1 (en) | 2009-02-27 | 2015-08-28 | Bearing assemblies and bearing apparatuses |
Applications Claiming Priority (4)
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US12/394,489 US8277124B2 (en) | 2009-02-27 | 2009-02-27 | Bearing apparatuses, systems including same, and related methods |
US13/599,752 US8616770B2 (en) | 2009-02-27 | 2012-08-30 | Bearing apparatuses, systems including same, and related methods |
US14/079,218 US9145735B2 (en) | 2009-02-27 | 2013-11-13 | Methods of operating bearing apparatuses |
US14/839,328 US20150369283A1 (en) | 2009-02-27 | 2015-08-28 | Bearing assemblies and bearing apparatuses |
Related Parent Applications (1)
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US14/079,218 Continuation US9145735B2 (en) | 2009-02-27 | 2013-11-13 | Methods of operating bearing apparatuses |
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US20150369283A1 true US20150369283A1 (en) | 2015-12-24 |
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US13/599,752 Active US8616770B2 (en) | 2009-02-27 | 2012-08-30 | Bearing apparatuses, systems including same, and related methods |
US14/079,218 Active US9145735B2 (en) | 2009-02-27 | 2013-11-13 | Methods of operating bearing apparatuses |
US14/839,328 Abandoned US20150369283A1 (en) | 2009-02-27 | 2015-08-28 | Bearing assemblies and bearing apparatuses |
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US13/599,752 Active US8616770B2 (en) | 2009-02-27 | 2012-08-30 | Bearing apparatuses, systems including same, and related methods |
US14/079,218 Active US9145735B2 (en) | 2009-02-27 | 2013-11-13 | Methods of operating bearing apparatuses |
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EP (1) | EP2401463B1 (en) |
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DE (1) | DE202010002867U1 (en) |
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WO2010098951A2 (en) | 2010-09-02 |
US8616770B2 (en) | 2013-12-31 |
US8277124B2 (en) | 2012-10-02 |
US20120325560A1 (en) | 2012-12-27 |
EP2401463A2 (en) | 2012-01-04 |
CN202706909U (en) | 2013-01-30 |
EP2401463B1 (en) | 2017-03-22 |
US20140072249A1 (en) | 2014-03-13 |
US9145735B2 (en) | 2015-09-29 |
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