An earth-boring tool may include a tool body and a coupling region configured to couple the earth-boring tool to an adjacent portion of a drill string. The earth-boring tool may also include one or more sensors disposed on the tool body. The earth-boring tool may further include a connector disposed in the coupling region electrically connected to the one or more sensors. The connector may be configured to enable a removable connection from an external device to the one or more sensors.

A drill bit device may include a cutter housing delimited by an outermost surface and various walls forming a socket. The drill bit device may include various main cutters disposed on an outermost surface of the cutter housing. The various main cutters may be configured to move in an outward direction upon receiving a predetermined pressure. The drill bit device may include various pre-charged cutters disposed immediately behind the various main cutters inside the cutter housing. The various pre-charged cutters may be configured to move in the outward direction upon receiving the predetermined pressure. The drill bit device may include a gate that connects the cutter housing to an internal groove that may be directly connected to a port switch that may allow release of the predetermined pressure through the internal groove and into the gate.

A drill bit device may include a cutter housing delimited by an outermost surface and various walls forming a socket. The drill bit device may include various main cutters disposed on an outermost surface of the cutter housing. The various main cutters may be configured to move in an outward direction upon receiving a predetermined pressure. The drill bit device may include various pre-charged cutters disposed immediately behind the various main cutters inside the cutter housing. The various pre-charged cutters may be configured to move in the outward direction upon receiving the predetermined pressure. The drill bit device may include a gate that connects the cutter housing to an internal groove that may be directly connected to a port switch that may allow release of the predetermined pressure through the internal groove and into the gate.

A drilling tool for drilling a wellbore in a formation, where the drilling tool includes: a drill bit comprising a cutting element, a sensor array, and a controller. The sensor array includes: an acoustic emissions (AE) sensor configured to measure an acoustic signal generated during drilling of the formation by the cutting element and a load sensor configured to measure an applied load by the cutting element on the formation. The controller is communicably connected to the sensor array and configured to determine a toughness of the cutting element using the acoustic signal, the applied load, and a wear state.

A system having an instrumented cutter of a drill bit including an on-cutter sensor for monitoring drilling performance metrics while performing drilling operations based on offset well data and a computing device is disclosed. The computing device executes a model development system configured to use the drilling performance metrics, surface drilling parameters, and characteristics of the instrumented cutter to train a machine learning (ML) model. The trained ML model is used to optimize drilling parameters and predict drill bit performance in a current well.

A Polycrystalline Diamond Compact (PDC) cutter for a rotary drill bit is provided with an integrated sensor and circuitry for making measurements of a property of a fluid in the borehole and/or an operating condition of the drill bit. A method of manufacture of the PDC cutter and the rotary drill bit is discussed.

A rotary tool for operation within an underground wellbore or within tubing in a wellbore has at least one force-sensitive element attached to the tool body and positioned to contact the conduit wall, wherein the force-sensitive element comprises an outer portion to contact the wellbore or tubing wall, at least one connecting portion which is more compliant than the outer portion and through which the outer portion is connected to the tool body, and at least one sensor responsive to force on the outer portion transmitted through the force-sensitive element to the tool body. The sensors may resolve forces into measurable forces on three axes. Possible rotary tools include drill bit, reamer, mill, stabilizer and rotary steerable system for a drill bit.

A rotary tool for operation within an underground wellbore or within tubing in a wellbore has at least one force-sensitive element attached to the tool body and positioned to contact the conduit wall, wherein the force-sensitive element comprises an outer portion to contact the wellbore or tubing wall, at least one connecting portion which is more compliant than the outer portion and through which the outer portion is connected to the tool body, and at least one sensor responsive to force on the outer portion transmitted through the force-sensitive element to the tool body. The sensors may resolve forces into measurable forces on three axes. Possible rotary tools include drill bit, reamer, mill, stabilizer and rotary steerable system for a drill bit.

Methods and systems are described for drilling a wellbore. A method includes: sensing electrical resistance of an insulated conductor extending from a surface of a drill bit to a sensor inside the drill bit; calculating drill bit dimensions based on the sensed electrical resistance; and transmitting sensed electrical resistance, calculated drill bit dimensions, or both uphole to a system for controlling drilling operations.

Methods and systems are described for drilling a wellbore. A method includes: sensing electrical resistance of an insulated conductor extending from a surface of a drill bit to a sensor inside the drill bit; calculating drill bit dimensions based on the sensed electrical resistance; and transmitting sensed electrical resistance, calculated drill bit dimensions, or both uphole to a system for controlling drilling operations.