Abstract: Methods and apparatus are disclosed for retaining components in a downhole motor in the event of a mechanical separation or failure of one or more components therein. As described, the retention mechanism does not require a threaded connection to components of the mud motor drivetrain. Downhole motor assemblies including the new catch mechanism also include a structural element to engage the catch assembly and the components to which it is attached in the event of a mechanical failure within the mud motor assembly.

Abstract: A mud motor, system, and method for using same are disclosed. A mud motor can include a continuously formed power section stator housing having a first end, a second end, and an internal cavity comprising a series of stator lobes and a housing portion passing. The stator lobes can extend from the first end of the power section stator housing until a first end of a transition portion. The transition portion can form a unitary combination with the stator lobes. The mud motor further includes a rotor assembly including a power section rotor having rotor lobes to be disposed completely within the internal cavity. Additional apparatuses, systems, and methods are disclosed.

Abstract: A catch assembly is provided for a downhole motor assembly of a drilling system. The catch assembly may include a catch basket that may be coupled to a saver sub. The saver sub may be coupled to a stator tube housing a rotor of a downhole motor. The rotor knob may be coupled to the rotor and include a flange that may be positioned in the catch basket. The flange may be positioned uphole of an internal shoulder of the catch basket. Subsequent to a connection failure in or near the stator tube, the flange may engage the internal shoulder of the catch basket to prevent the rotor from falling downhole.

Abstract: A bearing assembly for a downhole drilling motor can include a housing having an inner wall, an outer bearing race within the housing, and an inner bearing race. The outer bearing race can include a reduced-diameter portion forming a gap between the outer bearing race and the inner wall of the housing to allow for radial displacement of the outer bearing race relative to the housing. The design combines the functions of a bearing and a compliant feature into a single unit.

Abstract: A drilling assembly includes a straight housing in which a mud motor assembly is mounted. The mud motor includes a rotor that rotates within a stator. The rotor has an axial centerline substantially parallel with the housing. A drivetrain is coupled between the rotor and a driveshaft. The driveshaft is coupled to a drill head. The driveshaft has a centerline that is non-coincident with (i.e., offset or angled) the axial centerline. The angle between the driveshaft centerline and the axial centerline may be fixed or variable. The angle may be variable in response to an axial force, imparted to the rotor, that is transferred to the driveshaft through the drivetrain. Additional apparatus, systems, and methods are disclosed.

Abstract: Various embodiments disclosed relate to bearing assembly for drilling a subterranean formation and methods of using the same. In various embodiments, the present invention provides a method of drilling a subterranean formation. The method includes flowing a drilling fluid through a drill string disposed in the subterranean formation, with the drill string including a bottom hole assembly including a bearing assembly including a low flow bearing. The method includes flowing a first part of the drilling fluid into contact with the low flow bearing, while simultaneously flowing a second part of the drilling fluid through a bypass channel around the low flow bearing. The method also includes discharging the first and second part of the drilling fluid between the bottom hole assembly and the subterranean formation.

Abstract: A drilling assembly includes a straight housing in which a mud motor assembly is mounted. The mud motor includes a rotor that rotates within a stator. The rotor has an axial centerline substantially parallel with the housing. A drivetrain is coupled between the rotor and a driveshaft. The driveshaft is coupled to a drill head. The driveshaft has a centerline that is non-coincident with (i.e., offset or angled) the axial centerline. The angle between the driveshaft centerline and the axial centerline may be fixed or variable. The angle may be variable in response to an axial force, imparted to the rotor, that is transferred to the driveshaft through the drivetrain. Additional apparatus, systems, and methods are disclosed.

Abstract: Various embodiments disclosed relate to bearing assembly for drilling a subterranean formation and methods of using the same. In various embodiments, the present invention provides a method of drilling a subterranean formation. The method includes flowing a drilling fluid through a drill string disposed in the subterranean formation, with the drill string including a bottom hole assembly including a bearing assembly including a low flow bearing. The method includes flowing a first part of the drilling fluid into contact with the low flow bearing, while simultaneously flowing a second part of the drilling fluid through a bypass channel around the low flow bearing. The method also includes discharging the first and second part of the drilling fluid between the bottom hole assembly and the subterranean formation.

Abstract: A downhole drilling motor, system, and method for using same are disclosed. A downhole drilling motor can include a power section stator having a first end, a second end, an internal cavity passing therethrough. The downhole drilling motor can further include a rotor assembly positioned and fully encased in the internal cavity. The rotor assembly includes a power section rotor, a drivetrain operably coupled to the power section rotor and a bearing set. The power section rotor is positioned at the first end within the internal cavity of the power section stator. The power section rotor, the drivetrain, and the bearing set are fully encased in the internal cavity of the power section stator. Additional apparatuses, systems, and methods are disclosed.

Abstract: A stabilizer device is provided for a mud motor drilling assembly. The stabilizer device may be mounted to a motor housing having one or more grooves or ridges. The stabilizer device may include a stabilizer body, a threader portion, and a clamp. The threaded portion may be positioned between the one or more grooves or ridges and the clamp. The threaded portion may include an external surface having threads. The threads on the external surface of the threaded portion of the stabilizer device may correspond to threads on an internal surface of a clamp. The threaded coupling of the clamp to the stabilizer device may couple the stabilizer device to the motor housing at the one or more grooves or ridges.

Abstract: A bearing assembly for a downhole drilling motor can include a housing having an inner wall, an outer bearing race within the housing, and an inner bearing race. The outer bearing race can include a reduced-diameter portion forming a gap between the outer bearing race and the inner wall of the housing to allow for radial displacement of the outer bearing race relative to the housing. The design combines the functions of a bearing and a compliant feature into a single unit. The design will also provide reliability of performance in high dogleg and short bit-to-bend applications where radial loads are extreme and bearings frequently fail.

Abstract: Multi-functional fluid-driven power generation units, modular power generation units, and drilling systems with a power generation unit are presented herein. A power generation unit for powering one or more downhole tools in a drill string is disclosed. The power generation unit includes a housing that is configured to couple to a downhole portion of the drill string and receive at least a portion of fluid flowing through the drill string. The power generation unit also includes a fluid-driven motor assembly with a drive shaft configured to output rotational drive forces generated by the motor assembly. An electrical generator is operatively coupled to the drive shaft and configured to convert the rotational drive forces generated by the motor assembly into electrical power. In addition, a hydraulic pump is operatively coupled to the drive shaft and configured to convert the rotational drive forces generated by the motor assembly into hydraulic power.

Abstract: A drilling apparatus including a tubular bearing housing, a tilted sleeve removably connected with the bearing housing, and a driveshaft. The bearing housing has a housing axis, a housing bore, and a housing bore axis. The housing bore axis is parallel with the housing axis. The tilted sleeve has a sleeve axis, a sleeve bore, and a sleeve bore axis. The tilted sleeve is connected with the bearing housing and is positioned within the housing bore. The sleeve axis is parallel with the housing bore axis and the sleeve bore axis is oblique to the sleeve axis. The driveshaft is rotatably supported within the sleeve bore. The driveshaft has a driveshaft axis. The driveshaft axis is parallel with the sleeve bore axis.

Abstract: A drilling assembly includes a straight housing in which a mud motor assembly is mounted. The mud motor includes a rotor that rotates within a stator. The rotor has an axial centerline substantially parallel with the housing. A drivetrain is coupled between the rotor and a driveshaft. The driveshaft is coupled to a drill head. The driveshaft has a centerline that is non-coincident with (i.e., offset or angled) the axial centerline. The angle between the driveshaft centerline and the axial centerline may be fixed or variable. The angle may be variable in response to an axial force, imparted to the rotor, that is transferred to the driveshaft through the drivetrain. Additional apparatus, systems, and methods are disclosed.

Abstract: Methods and apparatus are disclosed for retaining components in a downhole motor in the event of a mechanical separation or failure of one or more components therein. As described, the retention mechanism does not require a threaded connection to components of the mud motor drivetrain. Downhole motor assemblies including the new catch mechanism also include a structural element to engage the catch assembly and the components to which it is attached in the event of a mechanical failure within the mud motor assembly.

Abstract: A catch assembly is provided for a downhole motor assembly of a drilling system. The catch assembly may include a catch basket that may be coupled to a saver sub. The saver sub may be coupled to a stator tube housing a rotor of a downhole motor. The rotor knob may be coupled to the rotor and include a flange that may be positioned in the catch basket. The flange may be positioned up-hole of an internal shoulder of the catch basket. Subsequent to a connection failure in or near the stator tube, the flange may engage the internal shoulder of the catch basket to prevent the rotor from falling downhole.

Abstract: A stabilizer device is provided for a mud motor drilling assembly. The stabilizer device may be mounted to a motor housing having one or more grooves or ridges. The stabilizer device may include a stabilizer body, a threaded portion, and a clamp. The threaded portion may be positioned between the one or more grooves or ridges and the clamp. The threaded portion may include an external surface having threads. The threads on the external surface of the threaded portion of the stabilizer device may correspond to threads on an internal surface of a clamp. The threaded coupling of the clamp to the stabilizer device may couple the stabilizer device to the motor housing at the one or more grooves or ridges.

Abstract: A drilling apparatus including a tubular bearing housing, a tilted sleeve removably connected with the bearing housing, and a driveshaft. The bearing housing has a housing axis, a housing bore, and a housing bore axis. The housing bore axis is parallel with the housing axis. The tilted sleeve has a sleeve axis, a sleeve bore, and a sleeve bore axis. The tilted sleeve is connected with the bearing housing and is positioned within the housing bore. The sleeve axis is parallel with the housing bore axis and the sleeve bore axis is oblique to the sleeve axis. The driveshaft is rotatably supported within the sleeve bore. The driveshaft has a driveshaft axis. The driveshaft axis is parallel with the sleeve bore axis.

Abstract: A clamping assembly may include a split-ring device and bearing for coupling to a driveshaft. The split-ring device may comprise split-ring shells having protrusions on an interior radial surface for positioning in grooves adjacent to radial protrusions on the driveshaft. In some aspects, the split-ring shells may include tabs corresponding to cavities on a first bearing for coupling the split-ring shell to the first bearing. In other aspects, the split-ring shells may be sized to create one or more gaps when positioned on the driveshaft. The first bearing may include one or more corresponding tabs for positioning in the one or more gaps created by the split-ring shells. A second bearing may be threadably coupled to the first bearing to suppress the axial and rotational movement of the clamping assembly separate from the driveshaft.

Abstract: A downhole drilling motor, system, and method for using same are disclosed. A downhole drilling motor can include a power section stator having a first end, a second end, an internal cavity passing therethrough. The downhole drilling motor can further include a rotor assembly positioned and fully encased in the internal cavity. The rotor assembly includes a power section rotor, a drivetrain operably coupled to the power section rotor and a bearing set. The power section rotor is positioned at the first end within the internal cavity of the power section stator. The power section rotor, the drivetrain, and the bearing set are fully encased in the internal cavity of the power section stator. Additional apparatuses, systems, and methods are disclosed.