Abstract: The invention includes a retention system and method for stator magnet wires. In embodiments, the retention system includes a packing ring that can swell to a larger size following installation. In embodiments, the lubricant used in the motor causes the packing ring to swell. When the packing ring swells, it exerts pressure against the end turns of the stator magnet wires, and can contour to the shape of the wires so that there are no pressure points on the wires. A rigid support ring can be positioned concentric with the packing ring so that the packing ring does not swell toward the axis of the motor housing.

Abstract: An electrical submersible pump assembly has modules including a pump, at least one motor, and a pressure equalizer coupled to the motor. First and second ones of the modules have a threaded connection including a first adapter having threads. A second adapter mounted to the second module has a tubular body, a neck of smaller diameter than the body, an external shoulder at a base of the neck, a rim on the neck, and an external groove between the external shoulder and the rim. A collar is rotatably carried and axially movable on me neck, the collar being in threaded engagement with the threads of the first adapter, the collar having an internal groove. A split shoulder ring carried partly in the external groove and partly in the internal groove retains the collar on the neck and is biased into one of the grooves.

Abstract: Systems and methods for preventing rotation of rotor bearings in electric motors which enable retrofitting of conventionally designed bearings to use spring-loaded keys instead of elastomeric T-rings to prevent rotation while allowing axial movement of the bearings within a stator bore. An elongated, curved spring arm is positioned in the nesting groove at the outer periphery of the bearing. One end of the spring may be secured to the bearing by positioning an S-shaped bend in the spring arm through a hole in the floor of the nesting groove. A key at the opposite end of the spring arm is urged radially outward by the spring arm. The key may be positioned in a slot in the outer portion of the bearing, and the spring arm may be retained in the groove by a retaining pin installed in the groove.

Abstract: A submersible pump assembly includes a rotary pump and an electrical motor operatively connected to the pump for driving the pump. A seal section is connected between the motor and the pump for reducing a pressure differential between lubricant in the motor and hydrostatic well fluid pressure. A shaft assembly extends from the motor through the seal section and the pump. A sleeve surrounds the shaft assembly. A carrier body has an inner diameter surface. An anti-rotation member is on an exterior of the carrier body in static engagement with an inner diameter surface of the pump assembly for preventing rotation of the carrier body. An annular metal radially deflectable spring is located between and in contact with an outer diameter surface of the sleeve and with the inner diameter surface of the carrier body. The spring is a wave spring with undulations.

Abstract: Systems and methods for configuring stators for downhole electric motors, where a single master stator can be configured to function as multiple different types of stators. In one embodiment, a configurable stator has a plurality of magnet windings disposed within its body, wherein the windings are connected to a plurality of electrical terminals that are accessible from the exterior of the body of the stator. Each of the terminals is configured to enable any one of a plurality of different types of lead wires to be attached to it, thereby enabling the stator to be configured in various different ways. In one embodiment, the master stator can be configured as a single stator, an upper tandem stator, a middle tandem stator, or a lower tandem stator.

Abstract: Devices and methods for reversibly securing first and second component subs of submersible well pump assembly. First and second component subs are provided with connection end portions which are placed into a sealed abutting relation. A connecting collar is threaded onto the first component sub. A locking groove on the first component sub receives a locking dog therein.

Abstract: Systems and methods for rotor bearings that enable improved oil circulation, wherein axial grooves are formed in the outer periphery of each bearing to form channels that allow axial flow of oil through the channels. Each bearing includes a collar, a sleeve and an interference ring. The collar has a bore through its center in which a rotatable sleeve is positioned. The outer periphery of the collar has a circumferential groove and at least one axial groove that extends from one face of the collar to the other. An axially permeable interference ring positioned within the circumferential groove extends radially outward from the groove beyond the outer periphery of the collar. The interference ring (e.g., a looped coil spring) allows fluid in the axial groove to flow through the interference ring. The axial groove may have a different depth than the circumferential groove.

Abstract: Systems and methods for the construction of electric motors, where expandable material is inserted into the slots in which magnet wires are positioned and expanded in the slots to mechanically restrain the wires. One embodiment comprises a downhole electric motor such as might be used in an electric submersible pump (ESP) system. The motor has a stator with multiple slots in which magnet wires are positioned. A slot liner is positioned in each slot and an expansion pad is positioned in each slot between the slot liner and the slot wall nearest the bore of the stator. The wires are positioned inside the slot liner. When the motor is almost completely assembled, it is filled with oil. Some of the oil is absorbed by the expansion pads, which then expand to fill the unoccupied volume in the slots, thereby restraining the movement of the wires within the slots.

Abstract: Systems and methods for processing power provided to downhole electrical systems such as electric submersible pump motors to increase the power factor of the supplied power. In one embodiment, a system comprises a downhole motor and a power factor corrector. The motor may be coupled to drive an electric submersible pump. The power factor corrector is configured to receive input power, process the received input power using one or more capacitive electrical components and thereby impart a capacitive phase shift between the voltage and the current of the received input power. The processed output power is provided to the downhole motor, which consumes the processed output power with a power factor which is greater than it would have been in the absence of the correction.

Abstract: Systems and methods for rotor bearings that enable improved oil circulation, wherein axial grooves are formed in the outer periphery of each bearing to form channels that allow axial flow of oil through the channels. Each bearing includes a collar, a sleeve and an interference ring. The collar has a bore through its center in which a rotatable sleeve is positioned. The outer periphery of the collar has a circumferential groove and at least one axial groove that extends from one face of the collar to the other. An axially permeable interference ring positioned within the circumferential groove extends radially outward from the groove beyond the outer periphery of the collar. The interference ring (e.g., a looped coil spring) allows fluid in the axial groove to flow through the interference ring. The axial groove may have a different depth than the circumferential groove.

Abstract: A submersible pump assembly includes a rotary pump and an electrical motor operatively connected to the pump for driving the pump. A seal section is connected between the motor and the pump for reducing a pressure differential between lubricant in the motor and hydrostatic well fluid pressure. A shaft assembly extends from the motor through the seal section and the pump. A sleeve surrounds the shaft assembly. A carrier body has an inner diameter surface. An anti-rotation member is on an exterior of the carrier body in static engagement with an inner diameter surface of the pump assembly for preventing rotation of the carrier body. An annular metal radially deflectable spring is located between and in contact with an outer diameter surface of the sleeve and with the inner diameter surface of the carrier body. The spring is a wave spring with undulations.

Abstract: Systems and methods for the construction of electric motors, where multiple laminations within the stator core incorporate interlocking features such as dimples and corresponding depressions or recesses to prevent the laminations from rotating with respect to each other. The end laminations of the stack are welded to snap rings, and the snap rings are welded to the housing to prevent rotation of the laminations within the stator housing. The use of the interlocking features to prevent rotation of the laminations within the housing eliminates the need for compression of the laminations and the use of encapsulants to prevent rotation of the laminations.

Abstract: The invention includes a retention system and method for stator magnet wires. In embodiments, the retention system includes a packing ring that can swell to a larger size following installation. In embodiments, the lubricant used in the motor causes the packing ring to swell. When the packing ring swells, it exerts pressure against the end turns of the stator magnet wires, and can contour to the shape of the wires so that there are no pressure points on the wires. A rigid support ring can be positioned concentric with the packing ring so that the packing ring does not swell toward the axis of the motor housing.

Abstract: Systems and methods for the construction of electric motors, where expandable material is inserted into the slots in which magnet wires are positioned and expanded in the slots to mechanically restrain the wires. One embodiment comprises a downhole electric motor such as might be used in an electric submersible pump (ESP) system. The motor has a stator with multiple slots in which magnet wires are positioned. A slot liner is positioned in each slot and an expansion pad is positioned in each slot between the slot liner and the slot wall nearest the bore of the stator. The wires are positioned inside the slot liner. When the motor is almost completely assembled, it is filled with oil. Some of the oil is absorbed by the expansion pads, which then expand to fill the unoccupied volume in the slots, thereby restraining the movement of the wires within the slots.

Abstract: Systems and methods for processing power provided to downhole electrical systems such as electric submersible pump motors to increase the power factor of the supplied power. In one embodiment, a system comprises a downhole motor and a power factor corrector. The motor may be coupled to drive an electric submersible pump. The power factor corrector is configured to receive input power, process the received input power using one or more capacitive electrical components and thereby impart a capacitive phase shift between the voltage and the current of the received input power. The processed output power is provided to the downhole motor, which consumes the processed output power with a power factor which is greater than it would have been in the absence of the correction.

Abstract: A submersible electric motor has feature to enhance thermal conductivity from the motor interior to the exterior. The motor has a cylindrical housing and a stator rigidly mounted within housing. A rotatable rotor is located within the stator. A gap formed between the stator's outer diameter and the inner wall of the housing is filled with a high thermal conductivity material to improve heat transfer from the motor. The remaining portion of the housing may be filled with a dielectric lubricant that has lesser thermal conductivity than the high thermal conductivity material.

Abstract: Systems and methods for constructing electric motors in which a stator core includes inner and outer portions that enable slots for magnet windings to be open during construction and closed in the completed motor. One embodiment comprises a method in which an inner stator core having a plurality of slots is formed by stacking a set of laminations. The slots are open radially outward from an axis of the inner stator core and which are configured to accommodate turns of magnet wire. After the magnet wire is positioned in the open slots, an outer stator core comprising stacked laminations is positioned around the inner stator core, enclosing the slots. The inner and outer stator cores are then positioned within a housing and assembled into a downhole motor.

Abstract: Systems and methods for configuring stators for downhole electric motors, where a single master stator can be configured to function as multiple different types of stators. In one embodiment, a configurable stator has a plurality of magnet windings disposed within its body, wherein the windings are connected to a plurality of electrical terminals that are accessible from the exterior of the body of the stator. Each of the terminals is configured to enable any one of a plurality of different types of lead wires to be attached to it, thereby enabling the stator to be configured in various different ways. In one embodiment, the master stator can be configured as a single stator, an upper tandem stator, a middle tandem stator, or a lower tandem stator.

Abstract: Systems and methods for insulating the Y-points of three-phase electric motors commonly used in ESP systems, in which the Y-points are not grounded or tied to a reference voltage, and may consequently experience high voltages. One embodiment is an apparatus for insulating the Y-point of the motor using an electrically insulating enclosure. The enclosure has apertures that extend from a cavity therewithin the to the exterior of the enclosure. The cavity accommodates the Y-point of the motor. The conductors which are connected at the Y-point junction extend from the cavity to the coils of the three-phase motor, and possibly to an instrument package. Seals are formed at the apertures to provide an electrically insulating barrier between the Y-point and the exterior of the enclosure. The cavity may be filled with an insulating material such as potting compound or oil.

Abstract: A submersible electric motor has feature to enhance thermal conductivity from the motor interior to the exterior. The motor has a cylindrical housing and a stator rigidly mounted within housing. A rotatable rotor is located within the stator. A gap formed between the stator's outer diameter and the inner wall of the housing is filled with a high thermal conductivity material to improve heat transfer from the motor. The remaining portion of the housing may be filled with a dielectric lubricant that has lesser thermal conductivity than the high thermal conductivity material.