Abstract: Drill bits and methods for sampling sensor data associated with the state of a drill bit are disclosed. A drill bit for drilling a subterranean formation comprises a bit body and a shank. The shank further includes a central bore formed through an inside diameter of the shank and configured for receiving a data analysis module. The data analysis module comprises a plurality of sensors, a memory, and a processor. The processor is configured for executing computer instructions to collect the sensor data by sampling the plurality of sensors, analyze the sensor data to develop a severity index, compare the sensor data to at least one adaptive threshold, and modify a data sampling mode responsive to the comparison. A method comprises collecting sensor data by sampling a plurality of physical parameters associated with a drill bit state while in various sampling modes and transitioning between those sampling modes.

Abstract: A rock bit is formed with pockets for enhanced cutting element retention and support of cutting elements during operation of the rock bit. Portions of the pockets are carburized to increase a yield strength of the pockets, which also increases the retention of the cutting elements. The pockets are formed at a diameter that is slightly smaller than an outer diameter of the cutting elements. Portions of the pockets are then carburized. The pockets are heated until the diameter of the pockets is equal to the outer diameter of the cutting elements. After the rock bit has been cooled and cleaned, a material is placed in each pocket prior to installing the cutting elements. The material homogenizes support for the cutting elements during operation of the rock bit.

Abstract: A method of non-destructively identifying and characterizing defects in a rotary drill component is provided. The method includes providing a drill component and an ultrasonic test system including a phased array ultrasonic transducer (PAUT). The method also includes acoustically coupling the PAUT to a surface location, transmitting focused ultrasonic acoustic waves at the location into the PAUT and recording a reflected acoustic response corresponding to a portion of a predetermined volume of a microstructure of the component associated with the location on the surface. The method also includes storing the response and moving one of the transducer or the component to a plurality of unique locations representative of the predetermined microstructure and repeating these steps. The method also includes processing the responses and providing an output signal to an output device configured to provide an output indicative of differences in the output signal within the predetermined volume of the microstructure.

Abstract: In one aspect, a method of determining a corrected weight-on-bit is provided, which method, in one embodiment, may include: drilling a wellbore with the drill bit; determining a weight-on-bit while drilling the wellbore; determining a pressure differential across an effective area of the drill bit while drilling the wellbore; and determining the corrected weight-on-bit from the determined weight-on-bit and the determined pressure differential.

Abstract: Drill bits and methods for sampling sensor data associated with the state of a drill bit are disclosed. A drill bit for drilling a subterranean formation comprises a bit body and a shank. The shank further includes a central bore formed through an inside diameter of the shank and configured for receiving a data analysis module. The data analysis module comprises a plurality of sensors, a memory, and a processor. The processor is configured for executing computer instructions to collect the sensor data by sampling the plurality of sensors, analyze the sensor data to develop a severity index, compare the sensor data to at least one adaptive threshold, and modify a data sampling mode responsive to the comparison. A method comprises collecting sensor data by sampling a plurality of physical parameters associated with a drill bit state while in various sampling modes and transitioning between those sampling modes.

Abstract: A drill bit made according to one embodiment includes a bit body and at least one preloaded sensor in the bit body. In one aspect, the sensor may include a sensor element on a sensor body having a first end and a second end and wherein the sensor is preloaded after placing the sensor body in the bit body. In another aspect, the sensor may be preloaded outside the bit body and then placed in the bit body in a manner that enables the sensor to retain the preloading.

Abstract: A spindle assembly for supporting a drill bit for repair. The spindle assembly includes a plurality of stepped segments of ever-decreasing diameter above a base, each segment sized to be received in a bore of a service cap inserted in the shank of a bit to be repaired. An end-cap for carrying an electronics module includes an end-cap body comprising a bore of similar diameter to the service cap bore diameter, but having one or more lugs protruding radially thereinto to prevent a spindle segment from entering the end cap bore so that the drill bit cannot be supported on the spindle.

Abstract: A system for estimating a velocity of a downhole component is disclosed. The system includes: a sensor configured to produce a sensor signal that is proportional to at least one of a position and an acceleration of the downhole component; and a circuit in communication with the sensor and configured to receive the sensor signal and generate an output signal indicative of an instantaneous velocity of the downhole component. A method of estimating a velocity of a downhole component is also disclosed.

Abstract: A rock bit is formed with pockets for enhanced cutting element retention and support of cutting elements during operation of the rock bit. Portions of the pockets are carburized to increase a yield strength of the pockets, which also increases the retention of the cutting elements. The pockets are formed at a diameter that is slightly smaller than an outer diameter of the cutting elements. Portions of the pockets are then carburized. The pockets are heated until the diameter of the pockets is equal to the outer diameter of the cutting elements. After the rock bit has been cooled and cleaned, a material is placed in each pocket prior to installing the cutting elements. The material homogenizes support for the cutting elements during operation of the rock bit.

Abstract: Drill bits and methods of measuring drill bit conditions are disclosed. A drill bit for drilling a subterranean formation comprises a bit bearing at least one cutting element and adapted for coupling to a drill string. The drill bit may also comprise a chamber formed within the bit and configured for maintaining a pressure substantially near a surface atmospheric pressure while drilling the subterranean formation. In addition, the drill bit may comprise at least one optical sensor disposed in the chamber and configured for sensing at least one physical parameter exhibited by the drill bit while drilling a subterranean formation.

Abstract: A drill bit having a bit body includes one or more acoustic sensors that are configured to detect elastic waves when the drill bit is used for drilling a wellbore. The acoustic sensor may be configured to detect a sonic signature associated with a failure event. In further arrangements, the acoustic sensors may be configured to receive signals from a controlled acoustic source.

Abstract: A drill bit made according to one embodiment includes at least a gamma ray sensor configured to provide signals representative of a presence and/or amount of a naturally occurring gamma ray source when the drill bit is used for cutting into a formation. A circuit may be configured to process signals from the gamma ray sensor to provide an estimate a parameter relating to the naturally occurring gamma ray source, which may used for purposes such as optimizing drilling parameters and geosteering.

Abstract: A rock bit is formed with pockets for enhanced cutting element retention and support of the cutting elements during operation of the rock bit. Portions of the pockets are carburized to increase the yield strength of the pockets which also increases the retention of the cutting elements. The pockets are formed at a diameter that is slightly smaller than the outer diameter of the cutting elements. Portions of the pockets are then carburized. The pockets are heated until the diameter of the pockets is equal to the diameter of the cutting elements. After the cones have been cooled and cleaned, a material is placed in each pocket prior to installing the cutting elements. The material homogenizes support for the cutting elements during operation of the rock bit.

Abstract: A drill bit made according to one embodiment includes at least one of a weight sensor and a torque sensor configured to provide signals representative of the weight and torque on the drill bit when the drill bit is used for cutting into a formation. A circuit may be configured to process signals from the weight and torque sensors to provide an estimate the weight and torque on the bit when the drill bit used for cutting into the formation.

Abstract: An embodiment of an apparatus made according to the disclosure includes a drill bit that includes a tip on a bit body configured to contact a formation when the drill bit is utilized to cut into the formation and a sensor coupled to the tip to provide signals responsive to the displacement of the tip when the tip is in contact with the formation.

Abstract: A roller cone bit having a sealed lubricant reservoir between a roller cone and a head section. A journal sleeve is included on the head section that circumscribes the journal bearing surface of the head section. The sleeve can axially pivot on the head section, but does not rotate thereon. The reservoir is formed into a journal bearing surface of the head section body and may be sealed by placing a seal around its periphery that extends between the journal bearing surface and journal sleeve. Sealing the reservoir results in a hydrostatic condition therein and substantially equalized pressures.

Abstract: Drill bits and methods for sampling sensor data associated with the state of a drill bit are disclosed. A drill bit for drilling a subterranean formation comprises a bit body and a shank. The shank further includes a central bore formed through an inside diameter of the shank and configured for receiving a data analysis module. The data analysis module comprises a plurality of sensors, a memory, and a processor. The processor is configured for executing computer instructions to collect the sensor data by sampling the plurality of sensors, analyzing the sensor data to develop a severity index, comparing the sensor data to at least one adaptive threshold, and modifying a data sampling mode responsive to the comparison. A method comprises collecting sensor data by sampling a plurality of physical parameters associated with a drill bit state while in various sampling modes and transitioning between those sampling modes.

Abstract: Drill bits and methods for sampling sensor data associated with a state of a drill bit are disclosed. A drill bit for drilling a subterranean formation comprises a bit configured for receiving a data analysis module. The data analysis module comprises at least one sensor, a memory, and a processor. The processor is configured for executing computer instructions to filter information derived from sensor data in the drill bit to develop a piecewise polynomial curve of the sensor data. Filtering information derived for the sensor data comprises approximating a first derivative of a sensor data waveform, calculating a plurality of zeros for the first derivative of the sensor data waveform, and fitting a cubic polynomial between adjacent zeros calculated from the first derivative of the sensor data waveform resulting in a piecewise cubic polynomial.

Abstract: Drill bits and methods for sampling sensor data associated with the state of a drill bit are disclosed. A drill bit for drilling a subterranean formation comprises a bit body and a shank. The shank further includes a central bore formed through an inside diameter of the shank and configured for receiving a data analysis module. The data analysis module comprises a plurality of sensors, a memory, and a processor. The processor is configured for executing computer instructions to collect the sensor data by sampling the plurality of sensors, analyzing the sensor data to develop a severity index, comparing the sensor data to at least one adaptive threshold, and modifying a data sampling mode responsive to the comparison. A method comprises collecting sensor data by sampling a plurality of physical parameters associated with a drill bit state while in various sampling modes and transitioning between those sampling modes.

Abstract: Drill bits and methods for sampling sensor data associated with the state of a drill bit are disclosed. A drill bit for drilling a subterranean formation comprises a bit body and a shank. The shank further includes a central bore formed through an inside diameter of the shank and configured for receiving a data analysis module. The data analysis module comprises a plurality of sensors, a memory, and a processor. The processor is configured for executing computer instructions to collect the sensor data by sampling the plurality of sensors, analyzing the sensor data to develop a severity index, comparing the sensor data to at least one adaptive threshold, and modifying a data sampling mode responsive to the comparison. A method comprises collecting sensor data by sampling a plurality of physical parameters associated with a drill bit state while in various sampling modes and transitioning between those sampling modes.