WO2011037561A1 - Ensembles stator et rotor ayant une meilleure performance - Google Patents

Ensembles stator et rotor ayant une meilleure performance Download PDF

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Publication number
WO2011037561A1
WO2011037561A1 PCT/US2009/057963 US2009057963W WO2011037561A1 WO 2011037561 A1 WO2011037561 A1 WO 2011037561A1 US 2009057963 W US2009057963 W US 2009057963W WO 2011037561 A1 WO2011037561 A1 WO 2011037561A1
Authority
WO
WIPO (PCT)
Prior art keywords
preform
stator
rotor
bladder
extruded
Prior art date
Application number
PCT/US2009/057963
Other languages
English (en)
Inventor
Jeremy B. Slay
John Snyder
Victor Gawski
Winston Webber
Original Assignee
Halliburton Energy Services, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Halliburton Energy Services, Inc. filed Critical Halliburton Energy Services, Inc.
Priority to PCT/US2009/057963 priority Critical patent/WO2011037561A1/fr
Priority to US12/876,515 priority patent/US8734141B2/en
Publication of WO2011037561A1 publication Critical patent/WO2011037561A1/fr

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C2/00—Rotary-piston machines or pumps
    • F04C2/08—Rotary-piston machines or pumps of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing
    • F04C2/10—Rotary-piston machines or pumps of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing of internal-axis type with the outer member having more teeth or tooth-equivalents, e.g. rollers, than the inner member
    • F04C2/107—Rotary-piston machines or pumps of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing of internal-axis type with the outer member having more teeth or tooth-equivalents, e.g. rollers, than the inner member with helical teeth
    • F04C2/1071—Rotary-piston machines or pumps of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing of internal-axis type with the outer member having more teeth or tooth-equivalents, e.g. rollers, than the inner member with helical teeth the inner and outer member having a different number of threads and one of the two being made of elastic materials, e.g. Moineau type
    • F04C2/1073—Rotary-piston machines or pumps of intermeshing-engagement type, i.e. with engagement of co-operating members similar to that of toothed gearing of internal-axis type with the outer member having more teeth or tooth-equivalents, e.g. rollers, than the inner member with helical teeth the inner and outer member having a different number of threads and one of the two being made of elastic materials, e.g. Moineau type where one member is stationary while the other member rotates and orbits
    • F04C2/1075—Construction of the stationary member
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C2230/00—Manufacture
    • F04C2230/20—Manufacture essentially without removing material
    • F04C2230/24—Manufacture essentially without removing material by extrusion
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
    • F04C2230/00—Manufacture
    • F04C2230/90—Improving properties of machine parts
    • F04C2230/91—Coating
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2225/00—Synthetic polymers, e.g. plastics; Rubber

Definitions

  • the present disclosure relates generally to Moineau- type helical positive displacement pumps and fluid motors and, in an embodiment described herein, more particularly provides for stator/rotor assemblies which have enhanced performance .
  • interference fit between an internal helically shaped rotor and an external stator having inwardly extending helically shaped lobes.
  • the interference fit enables the rotor to seal against the stator and form chambers which advance axially along the pump or motor as the rotor rotates
  • the interference fit is facilitated typically by making the stator lobes out of a resilient material, such as an elastomer or other polymer material.
  • stator linings are generally formed by an
  • FIG. 1 is a schematic view of a well drilling system embodying principles of the present disclosure.
  • FIG. 2 is an enlarged scale schematic cross-sectional view of a stator/rotor assembly used in the well drilling system, taken along line 2-2 of FIG. 1, the stator/rotor assembly embodying principles of the present disclosure.
  • FIG. 3 is a cross-sectional view of another
  • FIG. 4 is a schematic elevational view of initial steps in a method of constructing a stator/rotor assembly, a stator lining being extruded from an extruder.
  • FIG. 5 is a schematic elevational view of further steps in the method, the stator lining being installed within a stator housing.
  • FIG. 6 is a schematic elevational view of further steps in the method, a rotor sheath being installed on a rotor mandrel .
  • FIG. 7 is a schematic cross-sectional view of another construction of a stator for the stator/rotor assembly.
  • FIG. 8 is a schematic cross-sectional view of another construction of a rotor for the stator/rotor assembly.
  • FIG. 9 is a schematic elevational view of initial steps in another version of the method, the stator lining being extruded from an extruder.
  • FIG. 10 is a schematic elevational view of further steps in the other version of the method, the stator lining being installed within a stator housing.
  • FIG. 11 is a schematic elevational view of initial steps in yet another version of the method, the stator lining being extruded from an extruder.
  • FIG. 12 is a schematic elevational view of further steps in the FIG. 11 version of the method, the stator lining being installed within a stator housing.
  • FIG. 13 is a schematic cross-sectional view of another construction of a stator for the stator/rotor assembly.
  • FIG. 14 is a schematic cross-sectional view of another construction of a stator for the stator/rotor assembly.
  • FIG. 15 is a schematic cross-sectional view of another construction of a rotor for the stator/rotor assembly.
  • FIG. 1 Representatively illustrated in FIG. 1 is a well drilling system 10 which embodies principles of the present disclosure.
  • the system 10 includes a Moineau-type fluid motor, known to those skilled in the art as a "mud motor" 12.
  • the mud motor 12 is used to drive a drill bit 14 for drilling a wellbore 16.
  • the mud motor 12 and drill bit 14 are connected at a lower end of a tubular drill string.
  • Drilling fluid (typically referred to as "mud") is
  • pressurized fluid causes a rotor 18 to rotate within a stator 20.
  • the rotor 18 is connected to the drill bit 14, and so rotation of the rotor causes the drill bit to rotate, in order to drill the wellbore 16.
  • the mud motor 12 as shown in FIG. 1 includes a
  • stator/rotor assembly 22 which comprises at least the rotor 18 and the stator 20.
  • the rotor 18 rotates about its longitudinal axis relative to the stator 20 in response to fluid flow through the assembly 22.
  • fluid may flow through the assembly 22 in response to rotation of the rotor 18 relative to the stator 20.
  • Moineau-type devices can be
  • stator 20 rotates relative to the rotor 18 (either in response to fluid flow through a stator/rotor assembly, or in order to cause fluid to flow through the stator/rotor assembly).
  • stator is not used herein necessarily to require rotation of such a structure
  • stator is not used herein necessarily to require that such a structure remain stationary, during operation of a stator/rotor assembly. Instead, there is merely relative rotation between a rotor and a stator, with the rotor being positioned within the stator.
  • FIG. 2 an enlarged scale schematic cross-sectional view of one configuration of the stator/rotor assembly 22 is representatively illustrated.
  • the rotor 18 has one outwardly extending helically shaped lobe 24 .
  • the stator 20 includes an outer tubular stator housing 26 and an inner stator lining 28 . Two inwardly extending lobes 30 are formed in the stator lining 28 . Between the rotor 18 and the stator lining 28 is formed a cavity 32 which displaces axially through the stator/rotor assembly 22 in response to relative rotation between the rotor and stator 20 .
  • the stator lining 28 is produced by extruding the stator lining as a preform 34 (see FIGS. 4 , 9 & 12 ) with the lobes 30 already formed therein.
  • the lobes 30 may be helically formed in the preform 34 as it is extruded, or the lobes may extend linearly in the preform, and then the preform may be twisted about its longitudinal axis to helically orient the lobes therein.
  • the stator lining 28 may be made of any suitable material which can be successfully extruded. Such materials are of much wider scope than those typically used in
  • the materials may have higher viscosity and/or higher molecular weight than those which may be used in injection molding.
  • tougher and more durable materials may be used for the extruded stator lining 28 , as opposed to typical injection molded stator linings.
  • stator lining 28 can be bonded to the stator housing 26 by compressing the stator lining between the housing and a bladder 36 (see FIGS. 7 , 8 & 13 ) .
  • a pressure differential across the bladder 36 is applied to compress the stator lining 28 against the housing 26 , and the stator lining can be cured while being
  • stator lining 28 could be compressed against the housing 26 in other ways, such as by applying pressure directly to the stator lining (e.g., hydraulically, mechanically or by use of centrifugal force).
  • Pressure can be applied, for example, using rollers or dies.
  • Centrifugal force apply pressure, for example, via use of a centrifuge.
  • the fluid used to apply the pressure to the stator lining 28 can be provided with treatments for the elastomer.
  • treatments can include PTFE particles for impregnating the elastomer with
  • the elastomer can be improved by such treatments while it is being compressed against the housing 26 (or the rotor mandrel 44 described below) .
  • the hydraulic fluid used to apply the pressure to the stator lining 28 could, for example, comprise a heat resistant fluid, such as silicone fluid.
  • a heat resistant fluid such as silicone fluid.
  • hot isostatic pressing may be used, with pneumatics or hydraulics to apply the pressure.
  • the stator housing 26 is preferably made of a
  • the stator lining 28 is preferably made of a tough and durable resilient polymer material, such as nitrile (NBR or XNBR) , hydrogenated acrylonitrile butadiene (HNBR, HSN or XHNBR) , fluorocarbon (FKM), base resistant elastomers (FEPM) or tetrafluoroethylene and propylene
  • FEPM perfluoroelastomer
  • EPDM ethylene propylene diene
  • silicone silicone
  • fluorosilicone natural rubber, polychloroprene rubber (CR), ethylene propylene (EP), epichlorohydrin, other "rubber” compounds, (PPS), polyetheretherketone (PEEK),
  • PEAK polyetheralkylketone
  • PEKK polyetherketone-ketone
  • PSU polysulphones
  • PI polyimide
  • PA polyamide
  • PEI polyetherimide
  • thermoplastic elastomers thermosets, other elastomers, thermoplastic vulcanates, phenolics, butyl rubber,
  • PVDF polyvinylidene fluoride
  • the nano particles 38 could, for example, comprise carbon black and/or silica particles.
  • FIG. 3 The assembly 22 of FIG. 3 differs from that of FIG. 2 in various ways. Most apparent is that, as depicted in FIG. 3 , the rotor 18 has four lobes 24 and the stator 20 has five lobes 30 .
  • stator 20 preferably has one more lobe 30 than the number of lobes 24 on the rotor 18 .
  • stator lining 28 has a substantially consistent
  • stator lining 28 in this example forms an inner
  • the thickness of the stator lining 28 varies by no more than approximately ⁇ 10 % about the interior of the stator housing 26 , but could vary as much as ⁇ 200 % about the stator housing, in keeping with the principles of this disclosure.
  • stator housing 26 it is necessary for the stator housing 26 to have the profile 40 formed internally therein.
  • the interior of the housing 26 could be cylindrically shaped, as depicted for the housing in FIG. 2 , with the stator lining 28 also having a cylindrically shaped exterior.
  • the lobes 24 on the rotor 18 are formed on an outer sheath 42 bonded to the exterior of a rotor mandrel 44.
  • the rotor mandrel 44 has an external helically extending profile 46 formed thereon, with the sheath 42 forming an outer
  • the rotor mandrel 44 is preferably made of a relatively high strength ductile material (such as various grades of steel, etc.), although other materials may be used, if desired.
  • the rotor sheath 42 is preferably made of a tough and durable resilient polymer material, such as any of the materials mentioned above for the stator lining 28,
  • the preform 34, the stator lining 28 and/or the rotor sheath 42 could be made of materials other than polymer materials. These other materials could include metals (whether or not powdered) , graphitic
  • crystalline polymers could be used, as well. Any
  • the rotor sheath 42 may be produced by extruding the material from an extruder.
  • the lobes 24 may be helically formed on the rotor sheath 42 as it is extruded, or the rotor sheath may have the lobes extending linearly along the preform 34 as it is extruded, and then the rotor sheath may be twisted about its longitudinal axis to helically orient the lobes.
  • the preform 34 used as the stator lining 28 or rotor sheath 42 may have a cylindrical tubular shape when it is extruded. Then, the preform 34 takes the shape of the internal profile 40 in the stator housing 26 or the external profile 46 on the rotor mandrel 44 when positioned in the stator housing or on the rotor mandrel.
  • the preform 34 is heated when it is cured and while it is being compressed against the stator housing 26 or rotor mandrel 44.
  • heat may be applied by various techniques, for example, electrical resistance heating, mocrowave heating, etc.
  • the preform 34 may be cured prior to being bonded to the stator housing 26 or rotor mandrel 44.
  • the bonding of the preform 34 to the stator housing 26 or rotor mandrel 44 may or may not require application of heat.
  • the preform 34 is preferably extruded so that it has a shape which will conform complementarily to the rotor mandrel 44 or stator housing 26, respectively, the preform is then heated, deformed, cooled so that it retains its deformed shape, installed on the rotor mandrel or in the stator housing, and then again heated so that it tends to return to its original shape.
  • the shape memory polymer preform 34 when used for the rotor sheath 42, the shape memory polymer preform 34 would be initially extruded such that its interior lateral dimension is smaller than the exterior dimension of the rotor mandrel 44. The preform 34 would then be heated, radially enlarged, cooled so that it retains its radially enlarged shape, slid onto the rotor mandrel 44, and then heated again, so that it tends to return to its original shape, thereby shrink-fitting the preform onto the rotor mandrel.
  • the shape memory polymer preform 34 When used for the stator lining 28 , the shape memory polymer preform 34 would be initially extruded such that its exterior lateral dimension is greater than the internal lateral dimension of the stator housing 26 . The preform 34 would then be heated, axially stretched so that it is radially reduced, cooled so that it retains its radially reduced shape, slid onto the stator housing 26 , and then heated again, so that it tends to return to its original shape, thereby tightly securing the preform into the stator housing .
  • appropriate preform material 48 is supplied to an extruder 50 which forces the material through a die 52 , thereby forming the preform 34 with a helical profile 54 .
  • the profile 54 is depicted in FIG. 4 as being an external profile (e.g., complementarily shaped relative to the internal profile 40 in the stator housing 26 ) , but an internal helically extending profile could be formed, as well.
  • the stator lining 28 as depicted in FIG. 2 could be extruded using the method of FIG. 4 , with the lobes 30 helically extending within the stator lining.
  • the extruder 50 preferably is of the twin screw type.
  • a binder mixed with the ceramic material is preferably
  • the extrusion process can yield a desirably isotropic grain structure .
  • the preform 34 is depicted being installed within the stator housing 26 of FIG. 3 .
  • the external profile on the preform 34 will complementarily engage the internal profile 40 in the stator housing 26 .
  • the preform 34 can be "threaded" into the stator housing 26 , or it could be collapsed radially, then
  • stator housing 26 installed in the stator housing 26 , and then radially expanded into engagement with the internal profile 40 .
  • FIG. 6 this process as applied to the rotor 18 is depicted, in the case where the preform 34 is used as the rotor sheath 42 .
  • the preform 34 is depicted in FIG. 6 as it is being installed onto the rotor mandrel 44 .
  • the preform 34 can be "threaded” onto the rotor mandrel 44 .
  • the rotor mandrel 44 depicted in FIG. 6 is of the one lobe 24 configuration of FIG. 2 . This demonstrates that any of the configurations of the rotor 18 described herein can be produced with the sheath 42 on the rotor mandrel 44 , in keeping with the principles of this
  • stator 20 is
  • stator lining 28 representatively illustrated after the preform 34 has been installed in the stator housing 26 , thereby forming the stator lining 28 .
  • a bladder 36 inside the stator lining 28 is used to compress the stator lining 28 against the stator housing 26 and thereby bond the stator lining to the
  • a pressure differential is preferably applied across the bladder 36 to produce the compression of the stator lining 28 .
  • increased pressure could be applied to the interior of the bladder 36 .
  • pressure between the bladder 36 and the housing 26 could be reduced (e.g., by pulling a vacuum between the bladder and the housing) to thereby produce the pressure differential across the bladder.
  • pressure can be applied directly to the stator lining 28 (e.g., hydraulically , mechanically or by use of
  • the bladder 36 could be complementarily shaped relative to the stator lining 28 and/or the stator housing 26 (e.g., with lobes similar to the lobes 30 helically extending thereon) prior to being installed in the stator lining.
  • the bladder 36 could have a tubular
  • the bladder could conform to the shape of the stator lining 28 and/or housing 26 when the differential pressure is applied across the bladder .
  • the rotor 18 is representatively illustrated after the preform 34 has been installed on the rotor mandrel 44 , thereby forming the rotor sheath 42 .
  • the bladder 36 is installed onto the rotor 18 and is used to compress the rotor sheath 42 against the rotor mandrel 44 and thereby bond the rotor sheath to the mandrel.
  • a pressure differential is preferably applied across the bladder 36 to produce the compression of the rotor sheath 42 .
  • increased pressure could be applied to the exterior of the bladder 36 .
  • pressure between the bladder 36 and the rotor mandrel 44 could be reduced (e.g., by pulling a vacuum between the bladder and the rotor mandrel) to thereby produce the pressure differential across the bladder.
  • the bladder 36 could be complementarily shaped relative to the rotor sheath 42 and/or the rotor mandrel 44 (e.g., with lobes similar to the lobes 24 helically extending thereon) prior to being installed on the rotor 18 .
  • the bladder 36 could have a tubular
  • the bladder 36 can be applied directly to the rotor sheath 42 (e.g.,
  • the method is depicted in another example, in which the profile 54 does not extend helically on the preform 34 when it is extruded from the extruder 50 . Instead, the profile 54 extends linearly along the longitudinal axis of the preform 34 .
  • the preform 34 is installed in the stator housing 26 .
  • the preform 34 may be twisted about its
  • the preform 34 could be twisted about its longitudinal axis after being installed in the stator housing 26 .
  • Yet another alternative is to install the preform 34 onto the bladder 36 having a shape complementary to the profile 40 in the stator housing 26 . Then, the bladder 36 with the preform 34 thereon can be installed in the stator housing 26 and the pressure differential applied across the bladder, so that the bladder and preform conform to the internal profile 40 in the stator housing. This technique can be used whether or not the profile 54 is formed on the preform 34 when it is extruded from the extruder 50.
  • the profile 54 is not formed on the preform 34 when it is extruded from the extruder 50.
  • the preform 34 could have a cylindrical shape with a substantially
  • the preform 34 is installed in the stator housing 26. At this time, as depicted in FIG. 12, the preform 34 still does not have the profile 54 formed
  • the preform 34 conforms to the shape of the profile 40 in the stator housing 26 when the pressure differential is applied across the bladder 36 and the preform is compressed against the housing. If the bladder 36 is not used, pressure can be applied directly to the preform 34 (e.g., hydraulically, mechanically or by use of centrifugal force).
  • the preform 34 could be installed onto the bladder 36 having a shape complementary to the profile 40 of the stator housing 26, at which time the preform 34 could take the complementary shape of the bladder 36 and profile 40.
  • the preform 34 may take a shape complementary to the profile 40 only after the pressure differential is applied across the bladder 36.
  • the preform 34 could be extruded with the profile 54 linearly formed thereon (as depicted in FIG. 9) or with no profile (as depicted in FIG. 10), and installed on the rotor mandrel 44.
  • the preform 34 could take the shape of the external profile 46 of the rotor mandrel 44 upon
  • stator lining 28 and/or rotor sheath 42 is cured (e.g., by applying heat, exposing to UV radiation, microwaves, pressure, etc.) while the stator lining and/or rotor sheath is compressed against the respective stator housing 26 or rotor mandrel 44.
  • the polymer material should have achieved
  • stator lining 28 and/or rotor sheath 42 bonded securely to the respective stator housing 26 or rotor mandrel 44.
  • stator 20 is representatively illustrated, in which the stator lining 28 is again formed without injection molding. However, instead of using the preform 34, multiple strips 56 of polymer material are layered between the stator housing 26 and the bladder 36 in calendared fashion.
  • Seams between the strips 56 may be oriented as desired with respect to the lobes 30, and with respect to the adjacent layers of strips.
  • the strips 56 preferably extend helically along the length of the stator housing 26, but could extend linearly or in any other orientation, if desired.
  • the strips 56 can be installed onto the bladder 36 prior to installing the bladder with strips thereon into the stator housing 26.
  • the bladder 36 would preferably have a shape complementary to the internal profile 40 of the housing 26 prior to the strips 56 being installed onto the bladder.
  • the bladder 36 could have a generally tubular cylindrical shape when the strips 56 are installed thereon, and the bladder and strips could take on a shape complementary to the profile 40 when the pressure differential is applied across the bladder.
  • the strips 56 may be formed by an extrusion process.
  • the polymer material in the configuration of FIG. 13 is
  • the strips 56 are preferably cured while the strips 56 are compressed between the bladder 36 and the housing 26. During the curing process, the strips 56 combine to form the stator lining 28. The strips 56 are also bonded securely to the stator housing 26.
  • FIG. 13 is described above as being used for construction of the stator 20, it will be appreciated that the same techniques may be used for construction of the rotor 18.
  • the strips 56 could be applied to the exterior of the rotor mandrel 44, and the bladder 36 may be used to compress the strips between the bladder and the rotor mandrel during the curing process.
  • the strips 56 may be compressed against the rotor mandrel 44 or the housing 26 using pressure applied without use of the bladder 36 .
  • the pressure could be applied hydraulically, mechanically or by use of centrifugal force.
  • the stator 20 is representatively illustrated in another configuration.
  • the stator lining 28 includes multiple layers 60 , 62 . Although only two such layers 60 , 62 are illustrated, any number of layers may be used in keeping with the principles of this disclosure.
  • the inner layer 60 could comprise a relatively tough and tear resistant material for direct contact with the rotor 18 and the fluid flowing through the assembly 22 .
  • the outer layer 62 could comprise a relatively compliant and shock absorbing material for resiliently supporting the inner layer 60 and forming a transition between the inner layer and the housing 26 .
  • the layers 60 , 62 could be separately extruded and/or separately bonded in the stator housing 26 .
  • the layers 60 , 62 could be extruded as a single preform 34 and/or the layers could be together bonded in the stator housing 26 using any of the techniques described above.
  • the layers 60 , 62 could also be cured using any of the
  • the rotor sheath 42 is made up of the multiple layers 60 , 62 .
  • the layer 60 is an outer layer
  • the layer 62 is an inner layer.
  • the layers 60 , 62 can be formed, cured and bonded to the rotor mandrel 44 using any of the techniques described above.
  • the layers 60 , 62 can be extruded separately or together, cured prior to or after being installed on the rotor mandrel 44, and bonded separately or together on the rotor mandrel.
  • Stators motors for use in drilling applications are also known as "power sections” or “mud motors” and are comprised of single or multi lobe progressive cavity sections. Stator configurations can be used as pumps to transport fluid or as hydraulic motors to produce rotational motion.
  • the polymer elements can be made of materials including but not limited to elastomers, thermoplastic elastomers, thermoplastic vulcanates, other thermosets, and
  • thermoplastics These applications can be very demanding leading to failure of the stator motors because of the failure of the stator lining.
  • the polymer elements can have problems with swell, degradation, hysteresis, heat build up, fatigue, abrasion, bond degradation and tearing during service.
  • the above disclosure describes a novel manufacturing process for stator/rotor assemblies used in pumps and power sections.
  • the method involves the use of extruded preforms of polymer material rather than injection molding rubber into a stator housing or onto a rotor mandrel.
  • the bonding of an extruded polymer preform to a metal or other rigid material substrate allows greater variation of polymer properties compared to the current injection molded
  • This method allows one to eliminate the injection molding process for the molding of polymers to the interior of stator housings and the exterior of rotor mandrels. This is desirable because the injection molding process limits the types of suitable polymer compounds and ultimately the final system performance because first and foremost the compound must be injection moldable. Injection moldable compounds are designed to have low uncured viscosity which is attained through low reinforcement and the addition of processing aids, oils and plasticizers .
  • An extruded rubber preform does not require a low green viscosity, allowing one to use tougher compounds with improved impact, stress relaxation, compression set, tear, hysteresis, thermal conductivity, and bonding properties. This combination of improved properties will lead to
  • extruded polymer preforms are bonded in place to replace injection molded elements.
  • This process improves the manufacturablity of the polymer elements as well as the performance and service lifetime. Possible improvements include:
  • Extruded preforms can be made in traditional stator and rotor shapes such that the material thickness varies around the circumference to create the lobe profiles. 3. Extruded preforms can alternatively be provided as even thickness extrusions for the manufacture of even wall thickness elements.
  • the polymer material can be extruded into elements that are longer and thinner than anything available in an injection molded element.
  • the extrusion dies can be cut to make a helical extruded profile.
  • the preforms can be slid into stator housings or onto cylindrical or helical lobe profiled rotor mandrels to allow the extruded preform to retain its shape for storage.
  • the preforms can be homogenous and void free without the knitlines created in typical injection molding
  • a pressurized bladder can be inserted inside or outside the preform and used to apply compression pressure to the preform as it is bonded and/or cured inside the stator housing or on the rotor mandrel.
  • a vacuum could be pulled between the bladder and the stator housing or rotor mandrel.
  • a bladder may not be used, and pressure may be applied directly to the preform (either on the rotor or in the stator housing), e.g., hydraulically, mechanically or using centrifugal force.
  • a similar process can be used to bond the polymer element to the exterior of a rotor mandrel.
  • the bonding agents are better preserved because there is no smearing of the adhesive which can occur with the injection molding process. This significantly improves the manufacturing quality of the tool.
  • Prior injection molding processes involved applying adhesive in a stator housing, allowing the adhesive to dry, and then injecting an elastomer into the housing. However, the adhesive breaks down at -400 deg. F (-200 deg. C), a common temperature for injection molded elastomers, and the adhesive can be
  • the quality of the polymer preform is easily verified because the entire preform can be inspected for flaws after extrusion and before installation in the stator housing or on the rotor mandrel.
  • the light weight bladder will not deflect the polymer material leading to thin material below the bladder and thick material above.
  • the use of tougher, higher green modulus polymer material should also prevent this deflection and thin/thick spots.
  • An adhesive can be used to bond the preform to the rotor or stator housing, which adhesive bonds well to both the preform and the rotor or stator housing.
  • the adhesive can bond well to both an elastomer and metal, for example, an epoxy, etc.
  • a separate adhesive may not be used, but the adhesive may be included in the preform as an additive.
  • a stator/rotor assembly 22 which includes at least one extruded preform 34 bonded to at least one of a stator housing 26 and a rotor mandrel 44.
  • the extruded preform 34 may comprise a stator lining 28 having multiple lobes 30 formed thereon which sealingly engage a rotor 18.
  • a thickness of the extruded preform 34 may be substantially consistent.
  • the lobes 30 may be formed by variations in a thickness of the
  • One extruded preform 34 may be bonded to the stator housing 26, and another extruded preform 34 may be bonded to the rotor mandrel 44.
  • the extruded preform 34 may conform to a generally helical shape of the stator housing 26 and/or the rotor mandrel 44.
  • the extruded preform 34 may include nano particle 38 reinforcement therein.
  • the extruded preform 34 may comprise a polymer
  • the material may comprise a shape memory polymer material .
  • the extruded preform may comprise multiple layers 60, 62.
  • the multiple extruded preform layers 60, 62 may be bonded to at least one of the stator housing 26 and the rotor mandrel 44.
  • the layers 60, 62 may be made of
  • the extruded preform 34 may be impregnated with a lubricant.
  • the method includes extruding at least one preform 34, and bonding the preform 34 to at least one of a stator housing 26 and a rotor mandrel 44.
  • Bonding the preform 34 may be performed after extruding the preform 34.
  • Extruding the preform 34 may include extruding the preform 34 with at least one lobe 24 , 30 formed thereon.
  • the method may include twisting the preform 34 , thereby helically disposing the lobe 24 , 30 , after extruding the preform 34 .
  • Extruding the preform 34 may include extruding the preform 34 without a lobe formed thereon.
  • Extruding the preform 34 may include extruding the preform 34 such that it has a helical shape.
  • Extruding the preform 34 may include extruding the preform 34 with helical lobes 24 , 30 formed thereon.
  • Extruding the preform 34 may include extruding the preform 34 with a generally tubular shape having
  • the method may include conforming the preform 34 to at least one lobe 30 , 24 formed on the stator housing 26 and/or the rotor mandrel 44 .
  • Bonding the preform 34 may include compressing the preform 34 between a bladder 36 and the stator housing 26 and/or the rotor mandrel 44 .
  • Compressing the preform 34 may include applying a pressure differential across the bladder 36 .
  • Applying the pressure differential may include applying increased pressure to a side of the bladder 36 opposite the preform 34 .
  • Applying the pressure differential may include reducing pressure on a side of the bladder 36 facing the preform 34 .
  • the method may include curing the preform 34 while compressing the preform 34 .
  • the bladder 36 may have a generally helical shape.
  • the bladder 36 may have a generally tubular non-helical shape.
  • the method may include incorporating nano reinforcement particles 38 into the preform 34 .
  • the extruded preform 34 may comprise a stator lining 28 having multiple lobes 30 formed thereon.
  • the extruded preform 34 may be bonded to a stator housing 26 having multiple lobes 30 formed thereon.
  • a thickness of the extruded preform 34 may be
  • the lobes 30 may be formed by variations in a thickness of the extruded preform 34 .
  • a first extruded preform 34 may be bonded to the stator housing 26 , and a second extruded preform 34 may be bonded to the rotor mandrel 44 .
  • the extruded preform 34 may conform to a generally helical shape of the stator housing 26 and/or the rotor mandrel 44 .
  • Bonding the preform 34 may include compressing the preform 34 against at least one of the stator housing 26 and the rotor mandrel 44 by applying pressure to the preform 34 .
  • Applying pressure to the preform 34 may include impregnating the preform 34 with a treatment.
  • the treatment may include at least one of a lubricant and a reinforcement.
  • Curing the preform 34 may be performed prior to bonding the preform 34 .
  • Bonding the preform 34 may include bonding multiple layers 60 , 62 of the preform 34 to the stator housing 26 and/or rotor mandrel 44 .
  • the layers 60 , 62 may be made of respective different materials.
  • the extruded preform 34 may include a polymer material, a metal material and/or a ceramic material. If the preform 34 includes a polymer material, the material may comprise a shape memory polymer material .
  • the method includes applying multiple polymer strips 56 to a bladder 36 , and bonding the polymer strips 56 to a stator housing 26 while compressing the polymer strips 56 between the bladder 36 and the stator housing 26 .
  • the method is performed without injection molding.
  • the bladder 36 may be generally helical shaped.
  • the bladder 36 may have multiple lobes 30 formed thereon.
  • the lobes 24 , 30 may extend helically about the bladder 36 .
  • the method may be performed without injecting any polymer between the bladder 36 and the stator housing 26 .
  • Compressing the polymer strips 56 may include applying a pressure differential across the bladder 36 .
  • a method of constructing a rotor 18 is also described above.
  • the method includes applying multiple polymer strips 56 to a rotor mandrel 44 , and bonding the polymer strips 56 to the rotor mandrel 44 while compressing the polymer strips 56 between a bladder 36 and the rotor mandrel 44 .
  • the method is performed without injection molding.
  • the bladder 36 may be generally helical shaped.
  • the bladder 36 may have at least one lobe 24 formed therein.
  • the lobe 24 may extend helically in the bladder 36 .
  • Compressing the polymer strips 56 may include applying a pressure differential across the bladder 36 .

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)

Abstract

La présente invention se rapporte à un ensemble stator et rotor qui comprend au moins une préforme extrudée reliée à un carter de stator et/ou à un mandrin de rotor. Un procédé de fabrication d'un ensemble stator et rotor consiste à extruder au moins une préforme et à relier la préforme à un carter de stator et/ou à un mandrin de rotor. Un procédé de fabrication d'un stator consiste à appliquer de multiples bandes polymères à une vessie ; et à relier les bandes polymères à un carter de stator tout en comprimant les bandes polymères entre la vessie et le carter de stator sans effectuer un moulage par injection. Un procédé de fabrication d'un rotor consiste à appliquer de multiples bandes polymères au mandrin de rotor et à relier les bandes polymères au mandrin de rotor tout en comprimant les bandes polymères entre une vessie et le mandrin de rotor sans effectuer un moulage par injection.
PCT/US2009/057963 2009-09-23 2009-09-23 Ensembles stator et rotor ayant une meilleure performance WO2011037561A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
PCT/US2009/057963 WO2011037561A1 (fr) 2009-09-23 2009-09-23 Ensembles stator et rotor ayant une meilleure performance
US12/876,515 US8734141B2 (en) 2009-09-23 2010-09-07 Stator/rotor assemblies having enhanced performance

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2009/057963 WO2011037561A1 (fr) 2009-09-23 2009-09-23 Ensembles stator et rotor ayant une meilleure performance

Publications (1)

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WO2011037561A1 true WO2011037561A1 (fr) 2011-03-31

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2015158320A3 (fr) * 2014-04-14 2016-03-17 André Rogotzki Unité de pompe ajustable pour une pompe volumétrique
US10161187B2 (en) 2013-09-30 2018-12-25 Halliburton Energy Services, Inc. Rotor bearing for progressing cavity downhole drilling motor

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2240056A (en) * 1940-02-28 1941-04-29 Schmitz Michael Eccentric gear pump
JPH0242190A (ja) * 1988-08-01 1990-02-13 Hitachi Ltd スクリュ流体機械
US5171138A (en) * 1990-12-20 1992-12-15 Drilex Systems, Inc. Composite stator construction for downhole drilling motors
US20030173774A1 (en) * 1999-11-04 2003-09-18 Reynolds Harris A. Composite liner for oilfield tubular goods
US20050089430A1 (en) * 2003-10-27 2005-04-28 Dyna-Drill Technologies, Inc. Asymmetric contouring of elastomer liner on lobes in a Moineau style power section stator
US20080264593A1 (en) * 2007-04-27 2008-10-30 Olivier Sindt Rotor of progressive cavity appratus and method of forming
US20090152009A1 (en) * 2007-12-18 2009-06-18 Halliburton Energy Services, Inc., A Delaware Corporation Nano particle reinforced polymer element for stator and rotor assembly

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2240056A (en) * 1940-02-28 1941-04-29 Schmitz Michael Eccentric gear pump
JPH0242190A (ja) * 1988-08-01 1990-02-13 Hitachi Ltd スクリュ流体機械
US5171138A (en) * 1990-12-20 1992-12-15 Drilex Systems, Inc. Composite stator construction for downhole drilling motors
US20030173774A1 (en) * 1999-11-04 2003-09-18 Reynolds Harris A. Composite liner for oilfield tubular goods
US20050089430A1 (en) * 2003-10-27 2005-04-28 Dyna-Drill Technologies, Inc. Asymmetric contouring of elastomer liner on lobes in a Moineau style power section stator
US20080264593A1 (en) * 2007-04-27 2008-10-30 Olivier Sindt Rotor of progressive cavity appratus and method of forming
US20090152009A1 (en) * 2007-12-18 2009-06-18 Halliburton Energy Services, Inc., A Delaware Corporation Nano particle reinforced polymer element for stator and rotor assembly

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10161187B2 (en) 2013-09-30 2018-12-25 Halliburton Energy Services, Inc. Rotor bearing for progressing cavity downhole drilling motor
WO2015158320A3 (fr) * 2014-04-14 2016-03-17 André Rogotzki Unité de pompe ajustable pour une pompe volumétrique

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