Blade cap force modulation system for a drill bit

Abstract

The force modulation system for a drill bit includes a cutter, a blade cap, a cap retention device, and a first force member. The cutter or cutters fit in the blade cap, and the blade cap fits to the drill bit. The cap retention device exerts a cap retention force in a first direction. The first force member exerts a first force in a second direction. The cutting profile of the force modulation system is now variable in more than one direction so as to avoid excessive forces from more than one direction for each cutter on the blade cap. There can also be a second force member to exert a second force in the first direction for more variability of the cutting profile in the first direction and a third force member to exert a third force in an opposite second direction.

Claims

1. A force modulation system for a drill bit, comprising: a cutter being comprised of a cutter body having a cutting end, and a cutting surface made integral with said cutter body at said cutting end; a blade cap being comprised of a cap body having an anchor end, a holding end opposite said anchor end, a plurality of cap sides between said anchor end and said holding end, and a cap opening at said holding end, said cutter body being in removable slide fit engagement with said cap opening; a cap retention means fixedly engaged to at least two cap sides so as to exert a cap retention force in a first direction of said blade cap; a first force member positioned against said cap body so as to exert a first force in a second direction of said cap body, said second direction being angled offset to said first direction; a second force member positioned against said cap body so as to exert a second force in said first direction of said cap body; and a third force member positioned against said cap body so as to exert a third force in said second direction of said cap body opposite said first force member.

2. The force modulation system, according to claim 1, wherein said cutter is removably engaged with said blade cap, said cutting surface being extended from said blade cap so as to cut a rock formation.

3. The force modulation system, according to claim 1, wherein said blade cap is comprised of another cap opening, further comprising: another cutter having another cutter body being in removable slide fit engagement with said another cap opening.

4. The force modulation system, according to claim 1, wherein said second direction is orthogonal to said first direction.

5. The force modulation system, according to claim 1, wherein said first direction is a direction of movement of said cap body relative to the drill bit, and wherein said second direction is another direction of movement of said cap body relative to the drill bit.

6. The force modulation system, according to claim 1, wherein said cap retention force is greater than said second force.

7. The force modulation system, according to claim 1, wherein said first force member is made integral with said second force member and said third force member.

8. The force modulation system, according to claim 7, wherein said third force member is comprised of a first spring portion, a second spring portion, and a third spring portion between said first spring portion and said second spring portion, said second force member being comprised of said second spring portion, said third force member being comprised of said third spring portion.

9. The force modulation system, according to claim 1, wherein said cap body is a wedge, said holding end being an outer perimeter of said wedge, said cap sides being comprised of two flange portions extending from said outer perimeter to said anchor end, said cap retention means being fixedly engaged to said two flange portions.

10. The force modulation system, according to claim 9, wherein said anchor end is comprised of a pivot point on said two flange portions, and wherein said cap retention means is comprised of a retention pin inserted through said two flange portions at said anchor end.

11. The force modulation system, according to claim 10, wherein said first direction is radial from said pivot point, and wherein said second direction is tangent to said first direction.

12. A force modulation system for a drill bit, comprising: a cutter being comprised of a cutter body having a cutting end, and a cutting surface made integral with said cutter body at said cutting end; a blade cap being comprised of a cap body having an anchor end, a holding end opposite said anchor end, a plurality of cap sides between said anchor end and said holding end, and a cap opening at said holding end, said cutter body being in removable slide fit engagement with said cap opening; a cap retention means fixedly engaged to at least two cap sides so as to exert a cap retention force in a first direction of said blade cap; and a first force member positioned against said cap body so as to exert a first force in a second direction of said cap body, said second direction being angled offset to said first direction; a second force member positioned against said cap body so as to exert a second force in said first direction of said cap body; and a third force member positioned against said cap body so as to exert a third force in said second direction of said cap body opposite said first force member, wherein said cap body is a wedge, said holding end being an outer perimeter of said wedge, said cap sides being comprised of two flange portions extending from said outer perimeter to said anchor end, said cap retention means being fixedly engaged to said two flange portions.

13. The force modulation system, according to claim 12, wherein said second direction is orthogonal to said first direction, wherein said first direction is radial from said pivot point, wherein said second direction of said first force is tangent to said first direction, and wherein said second direction of said third force is tangent to said first direction, said second direction of said third force being opposite said first force.

14. The force modulation system, according to claim 12, wherein said first force member is made integral with said second force member and said third force member.

15. The force modulation system, according to claim 14, wherein said third force member is comprised of a first spring portion, a second spring portion, and a third spring portion between said first spring portion and said second spring portion, said second force member being comprised of said second spring portion, said third force member being comprised of said third spring portion.

16. The force modulation system, according to claim 14, said first force member and said third force member are adjacent to corresponding two flange portions, said second force member being between said holding end and said retention pin.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(1) FIG. 1 is a schematic sectional view of a prior art force modulation system.

(2) FIG. 2 is a schematic sectional view of an embodiment of the force modulation system according to an embodiment of the present invention.

(3) FIG. 3 is a schematic sectional view of an embodiment of the force modulation system according to another embodiment of the present invention.

(4) FIG. 4 is a schematic sectional view of an embodiment of the force modulation system according to still another embodiment of the present invention.

(5) FIG. 5 is a schematic sectional view of an embodiment of the force modulation system according to yet another embodiment of the present invention.

(6) FIG. 6 is a perspective view of the embodiment of the force modulation system, according to FIG. 3.

(7) FIG. 7 is an exploded perspective view of the embodiment of the force modulation system of FIG. 3 and FIG. 6 in a drill bit.

(8) FIG. 8 is a front perspective view of the embodiment of the assembled force modulation system of FIG. 7.

(9) FIG. 9 is a back perspective view of the embodiment of the assembled force modulation system of FIG. 7.

(10) FIG. 10 is a sectional view of the embodiment of the assembled force modulation system of FIG. 7.

DETAILED DESCRIPTION OF THE INVENTION

(11) Conventional force modulation systems are limited to one dimension and one direction. The cutter, or the cutter in a holder, moves up and down within a drill bit cavity formed to fit the cutter or holder. A spring sits at the bottom of the drill bit cavity. The spring is compressible so as to reduce the amount of force exerted on the cutter by the rock formation. The cutter maintains position within the drill bit cavity to withstand sufficient force to drill through rock, while avoiding excessive force that would damage the cutter. The in and out of the drill bit cavity direction is one dimensional, corresponding to excessive force from depth of cut of the drill bit. These force modulation systems cannot account for offset force vectors, such as those forces created on shoulder cutters at junctions between different types of rock materials in a rock formation. There can be excessive force from impact forces of the rock materials that would damage the cutter from a different direction than the one direction set by force modulation systems of the prior art.

(12) Referring to FIGS. 2-10, the force modulation system 10 for a drill bit includes a cutter 20 or plurality of cutters 20, a blade cap 30, a cap retention means 50, and a first force member 60. Each cutter 20 is comprised of a cutter body 22 having a cutting end 24, and a cutting surface 26 made integral with the cutter body 22 at the cutting end 24. The blade cap 30 is comprised of a cap body 32 having an anchor end 34, a holding end 36 opposite the anchor end 34, a plurality of cap sides 38 between the anchor end 34 and the holding end 36, and a cap opening 40 or plurality of cap openings 40 at the holding end 36. Each cutter body 22 is in removable slide fit engagement with a corresponding cap opening 40. The cutting surface 26 extends from the respective cap opening 40 so as to drill into rock formations.

(13) Each cutter 20 is removably engaged with the blade cap 30. The cutter 20 can be rotated within the respective cap opening 40 of the blade cap 30 so that each cutting surface 26 is adjusted relative to the respective cap opening 40. In addition to the adjustments between the blade cap 30 and the drill bit 15, the cutter 20 is rotatable for wear on the cutting surface 26 to be changed. There can be a plurality of cutters 20 in one blade cap 30. Each cutter 20 can be set in its own location and orientation relative to the blade cap 30.

(14) The force modulation system 10 includes the cap retention means 50 fixedly engaged to at least two cap sides 38 so as to exert a cap retention force in a first direction 42 of the blade cap 30. The cap retention means 50 removable engages more than one side of the blade cap 30. FIGS. 2-3 shows the two cap sides 38 opposite each other in one embodiment. FIGS. 2 and 3 show the first direction 42 as one direction of movement of blade cap 30 relative to the drill bit. The first direction is one direction of movement of the blade cap 30 relative to the drill bit 15, and the cap retention means 50 exerts the cap retention force in that first direction so as to prevent movement of the blade cap 30 in that first direction. The movement can be radially away and towards the drill bit. The cap retention means 50 can be a snap ring, shear pin, locking ring, locking pin, retention pin as in FIGS. 6-10, slot, screw or other known mechanical device to hold position of the blade cap 30.

(15) The first force member 60 can be an elastomeric insert, a plastic insert, metal mesh, disc spring, composite elastomeric insert, metal spring, hydraulic actuator, or other known mechanical devices to exert force on the holder 30 relative to the drill bit 15. FIGS. 6-10 show the first force member 60 as an elastomeric insert, such as a rubber insert. FIGS. 2-5 show the first force member 60 as a metal spring, and FIG. 5 shows an embodiment with a plurality of metal springs 60, 60. The first force member 60 is positioned against the blade cap 30 so as to exert a first force in a second direction 44 of the blade cap 30. The second direction 44 is angled offset to the first direction 42, as shown in FIGS. 2-5. FIG. 2 shows the first direction of the blade cap 30 by the cap retention means 50, and the second direction of the blade cap 30 by the first force member 60. FIG. 2 shows the second direction 44 as orthogonal to the first direction 42. FIG. 4 shows another embodiment of the first direction 42 of the blade cap 30 by the cap retention means 50, and the second direction 44 of the blade cap 30 by the first force member 60. FIG. 4 shows the second direction 44 as offset to the first direction 42. The angle of offset can range from 60 to 120 degrees. Relative to the drill bit, FIGS. 2-3 show the first direction 42 as vertical and the second direction 44 as horizontal, wherein the offset is orthogonal. FIGS. 2-3 may also be interpreted to show an orthogonal offset with the first direction 42 as radial and the second direction 44 as tangent to the first direction.

(16) The first direction 42 can be a direction of movement of the blade cap 30 relative to the drill bit 15, and the second direction 44 is another direction of movement of the blade cap 30 relative to the drill bit 15, including orthogonal to first direction 42. FIG. 2 shows the drill bit 15 and the dimensions of movement of the blade cap 30 relative to the drill bit 15. The cap retention force in the first direction 42 maintains position relative to the drill bit in the first direction 42. The first force in the second direction 44 determines the cutting profile of the force modulation system 10. The first force member 60 exerts a first force that is variable so that the cutters 20 avoid damage from excessive force in the second direction 44. Unlike the prior art systems, the second direction 44 of the first force member 60 is not the same as the first direction 42 for just depth of cut forces. The second direction 44 is offset angled so that excessive force of a different direction than the first direction 42 can be avoided. The cutters 20 avoid damage from impact forces from different rock materials. The first force member 60 in the position as shown is now more than just cumulative with the cap retention member 50 to help resist depth of cut force. There is a new relationship between the first force member 60 and the cap retention member 50. There is new functionality of the force modulation system 10 to avoid damage from excessive force from different angles on the cutters 20.

(17) FIGS. 3-5 show alternate embodiments of the force modulation system 10 of the present invention with a second force member 70 positioned against the blade cap 30 so as to exert a second force in the first direction 42 of the blade cap 30. In this embodiment, the cap retention member 50 can have the cap retention force greater than the second force with both in the first direction 42. The cap retention means 50 can be set as a breaking point before a critical amount of excessive force disables the cap retention means 50. To protect the snap ring from snapping or the retention pin from fracturing, the second force member 70 provides the second force in the first direction 42 as a supplement to the cap retention force in the first direction 42. The cutting profile is now variable in the first direction 42, according to the second force member 70. The cutter 20 can avoid the damage of excessive force in the first direction 42 related to depth of cut AND in the second direction 44 in the embodiment of FIGS. 3-5 related to impact forces from the joint of different rock materials. The second force member 70 can be cumulative and cooperative with the cap retention means 50 to resist depth of cut force. The second force member 70 is not completely cumulative with the first force member 60 in the second direction 44. The second force member 70 has a different placement and relationship to the holder 30 and cutter 20.

(18) FIG. 3 shows an embodiment with the second force member 70 completely cooperative with the cap retention means 50. The second force member 70 is aligned vertically with the cap retention means 50. FIGS. 4-5 show embodiments with the second force member 70 not completely cumulative with either the cap retention means 50 in the first direction 42 or the first force member 60 in the second direction 44. The second force in the second direction 44 is still offset from the first direction 42, but the second force only has a vector of force in the first direction 42. The second force member 70 can have a different placement and relationship to the blade cap 30 and cutter 20. FIG. 3 shows the first direction 42 as generally vertical and the second direction 44 as generally horizontal. FIGS. 4-5 are embodiments with the first direction 42 remaining generally vertical, while the second direction 44 is offset from the first direction 42 with at least of a vector of the second force in the first direction 42.

(19) FIGS. 6-10 show embodiments of the first force member 160 as being made integral with the second force member 170. As a rubber insert, there can be a first spring portion 162 and a second spring portion 172 with a hinge portion 180 between the first spring portion 162 and the second spring portion 172. The offset angled relationship as orthogonal for the first direction 42 and second direction 44 are also shown in FIGS. 3, 7, and 10, even with the first force member 160 and the second force member 170 being unitary.

(20) FIGS. 2-5 also show the alternate embodiments of the force modulation system 10 of the present invention with a third force member 80 positioned against the blade cap 30 so as to exert a third force in the second direction 44A of the blade cap 30 opposite to the first force. In this embodiment, the first force member 70 and the third force member 80 are opposite each other to avoid excessive force back and forth in the second direction 44 and opposite second direction 44A. Instead of a hard stop against the drill bit, the blade cap 30 can reduce excessive force in both the second direction 44 and the opposite second direction 44A of the blade cap 30 relative to the drill bit. The same back and forth avoidance of excessive force from depth of cut in the one direction relative to the drill bit can be achieved with the force modulation system 10 of the present invention. The first force member 60 and the third force member 80 provide a back and forth avoidance of excessive force from impacts at the junction of different rock materials in the rock formation. The force modulation system 10 can preserve the working life of the cutters 20 by avoiding excessive forces in multiple directions. FIG. 2 shows an embodiment of the system 10 with a first force member 60 and a third force member 80 and without a second force member 70. The cap retention means 50 can exert the first force in the first direction 42 without the second force member.

(21) FIGS. 4-5 further show embodiments with the third force member 80 not completely cumulative with either the cap retention means 50 in the first direction 42 or the first force member 60 in the second direction 44. The third force in the opposite second direction 44A is still offset from the first direction 42. The third force has a vector of force in the first direction 42 and another vector of force in the opposite second direction 44A.

(22) In the present invention, there are at least two directions, the first direction 42 and the second direction 44. The opposite second direction 44A is optional. However, the present invention includes more than a perfect separation of forces into a single direction. The cap retention force, the first force and the second force can be cooperative in the first direction 42 and the second direction 44, as long as there are multiple directions.

(23) FIGS. 6-10 show embodiments of the third force member 180, the first force member 160, and the second force member 170 as being made integral with each other. The second force member 170 is between the first force member 160 and the third force member 180. Whether an elastomeric insert, a plastic insert, metal mesh, composite elastomeric insert, or other known mechanical device to exert force on the blade cap 30 relative to the drill bit 15, the first force member 160 can be made integral with the second force member 170 and third force member 180. As an elastomeric or rubber insert, there can be a first spring portion 162, a second spring portion 172, and a third spring portion 182. The second spring portion 172 is between the first spring portion 162 and the third spring portion 182. The first spring portion 162 and the third spring portion 182 face opposite directions, corresponding to the second direction 44 for the first spring portion 162 and the opposite second direction 44A for the third spring portion 182. The offset angled relationship as orthogonal for the first direction 42 and second direction 44 and between the first direction 42 and the opposite second direction 44A are also shown in FIGS. 3, 7, and 10, even with the first force member 160, the second force member 170, and the third force member 180 being unitary.

(24) Alternate embodiments of the force modulation system 10 include the blade cap 30 in FIGS. 6-10 with the cap body 32 as a wedge 130. In this embodiment, the holding end 36 is an outer perimeter 136 of the wedge 130, and the plurality of cap sides 38 is comprised of two flange portions 138 extending from the outer perimeter 136 to the anchor end 34. The cap retention means 50 fixedly engaged the two flange portions 138 as the at least two cap sides of the blade cap 30. The two flange portions 138 are opposite each other. A section of the drill bit body extends between the two flange portions 138. FIGS. 6, 7, and 10 further show the anchor end 34 being comprised of a pivot point 134, wherein the cap retention means 50 is a retention pin 150 inserted through the two flange portions 138 at the anchor end 34. The retention pin 150 also inserts through the section of the drill bit body extended between the two flange portions 138. The retention pin 150 sets the first direction 42 as radial from the pivot point 134, while the second direction 44 and the opposite second direction 44A are tangent to the first direction 42. In this embodiment, the offset angled relationship between the first direction 42 and the second direction 44 is orthogonal as radial and tangent to the pivot point 134.

(25) For the embodiment of the wedge 130, the force modulation system 10 includes the third force member 180, the first force member 160, and the second force member 170 being made integral with each other. As in FIGS. 6-10, the second force member 170 is between the first force member 160 and the third force member 180. As an elastomeric or rubber insert, there can be a first spring portion 162, a second spring portion 172, and a third spring portion 182. The second spring portion 172 is between the first spring portion 162 and the third spring portion 182. The second spring portion 172 is placed between the drill bit and the outer perimeter 136. The first spring portion 162 fits inside one of the two flange portions 138, while the third spring portion 182 fits inside the remaining one of the two flange portions 138.

(26) The embodiment with the wedge 130 maintains the offset relationship of the first direction 42 and second direction 44 and the orthogonal relationship of the first direction 42 and the opposite second direction 44A. The first spring portion 162 and the third spring portion 182 face opposite directions on the two flange portions 138, corresponding to the second direction 44 for the first spring portion 162 and the opposite second direction 44A for the third spring portion 182. The orthogonal relationship of the first direction 42 as radial and second direction 44 as tangent and between the first direction 42 as radial and the opposite second direction 44A as tangent are also shown in FIGS. 3, 7, and 10, even with the first force member 160, the second force member 170, and the third force member 180 being unitary. The second force member 170 still avoids excessive force from depth of cut with the radial first direction 42 of the second force. The first force member 160 and the third force member 180 add the avoidance of excessive force from impact with joints between different rock materials with the tangent second direction 44 of the first force and the tangent opposite second direction 44A of the third force. Either the first force or the third force is exerted, depending on the direction of the impact force to be avoided.

(27) The present invention is a force modulation system for a drill bit. The system forms a variable cutting profile as the fixed cutters can have different contact on a rock formation while drilling. The cutting profile changes to avoid excessive force that would damage the fixed cutters. The force modulation system has particular usefulness for fixed cutters on the bit blade or shoulder of the drill bit. These cutters on the bit blade or shoulder of the drill bit typically drill the rock formation at junctions between different types of rock materials. There is a higher risk of excessive force to damage cutters at these joints. There is excessive force from depth of cut and impact from the different types of rock materials. The force modulation of the system can avoid these excessive forces from different directions.

(28) The present invention is a multi-directional force modulation system. Instead of being restricted to the one direction of in and out of the drill bit cavity, corresponding only to depth of cut, the system can also move cutters in another direction back and forth within the drill bit cavity. The cutting profile is variable in more than one dimension. In some embodiments, the first direction is set by a cap retention member relative to the drill bit, and the second direction is set by the first force member offset from the cap retention member. In other embodiments, there is a second force member that is set in the first direction to back up the cap retention member.

(29) The first direction and the second direction are angled offset from each other. The first and second directions can be orthogonal to each other. In alternate embodiments, forces are not completely aligned in a single direction. The first force is not in the first direction or the second direction. At least a vector of the first force must be in the second direction, not all of the first force. When the blade cap is a wedge, the first direction can be radial from a pivot point, while the second direction can be tangent to the first direction. There can also be an opposite second direction tangent to the first direction. The first force member and the third force member add the avoidance of excessive force from impact with joints between different rock materials with the tangent second direction of the first force and the tangent opposite second direction of the third force. Either the first force or the third force is exerted, depending on the direction of the impact force to be avoided. For prior art variable cutting profiles, there is no avoidance of excessive forces from more than one direction, and the avoidance only applies to excessive force from depth of cut. The variable cutting profiles of the prior art only compensate for a particular excessive force to avoid damage, instead of the different excessive forces from different directions. In the prior art systems, the one direction must be selected according to placement of the fixed cutter on the part of the drill bit. The multi-directional force modulation system can now avoid excessive force from more than one direction. The force modulation system of the present invention can be used for cutters in different parts of the drill bit, including the shoulder. The drill bit has an extended working life by avoid more excessive force on cutters than other prior art systems.

(30) The foregoing disclosure and description of the invention is illustrative and explanatory thereof. Various changes in the details of the illustrated structures, construction and method can be made without departing from the true spirit of the invention.