Abstract: Aspects of the subject technology relate to a sensor for a downhole tool. The downhole tool can include a collar and a sensor. The sensor can be secured to the collar for measuring one or more operational characteristics of the downhole tool during operation of the downhole tool. The sensor can include a substrate. The sensor can also include a plurality of strain gauges disposed on the substrate. The plurality of strain gauges can be configured to measure axial strains and torsional strains on the collar for measuring the one or more operational characteristics of the downhole tool.

Abstract: According to various aspects of the subject technology, a tool collar is provided. The tool collar may include a recessed portion comprising a component segment and a threaded segment, a pressure sleeve covering the recessed portion, and a threaded component mated to the threaded segment and configured to compress the pressure sleeve against a shoulder of a downhole tool. According to some aspects, a downhole tool is provided. The downhole tool may include a recessed portion comprising a component segment and a threaded segment, an unrecessed portion comprising a shoulder, a pressure sleeve covering the recessed portion of the downhole tool, and a threaded component mated to the threaded segment and configured to compress the pressure sleeve against the shoulder of the unrecessed portion.

Abstract: An electronics enclosure system includes a pressure housing with a thermally conductive material and a plurality of shells disposed within the pressure housing, wherein the plurality of shells are coupled together to form an enclosure, and wherein each shell of the plurality of shells comprises thermally conductive material. The electronics enclosure system further includes at least one circuit board secured to an inner surface of a respective shell of the plurality of shells and a plurality of electronic components secured to the at least one circuit board, the plurality of shells, or some combination thereof.

Abstract: The disclosure provides for a bottom hole assembly that comprises a housing and a caliper arm. The caliper arm is pivotally coupled to the housing at a hinge disposed within the housing, wherein the caliper arm is operable to rotate about the hinge between a first position within the housing and a second position external to the housing. The bottom hole assembly further comprises a linear actuator coupled to the caliper arm and operable to extend the caliper arm to the second position, wherein the caliper arm is biased to remain in the second position in contact with a borehole wall. The bottom hole assembly further comprises a sensor disposed within the housing and operable to monitor a position of the caliper arm.

Abstract: The disclosure provides for a bottom hole assembly that comprises a housing and a caliper arm. The caliper arm is pivotally coupled to the housing at a hinge disposed within the housing, wherein the caliper arm is operable to rotate about the hinge between a first position within the housing and a second position external to the housing. The bottom hole assembly further comprises a linear actuator coupled to the caliper arm and operable to extend the caliper arm to the second position, wherein the caliper arm is biased to remain in the second position in contact with a borehole wall. The bottom hole assembly further comprises a sensor disposed within the housing and operable to monitor a position of the caliper arm.

Abstract: Aspects of the subject technology relate to a sensor for a downhole tool. The downhole tool can include a collar and a sensor. The sensor can be secured to the collar for measuring one or more operational characteristics of the downhole tool during operation of the downhole tool including the performance characteristics of a drill motor. The sensor can include a substrate. The sensor can also include a plurality of strain gauges disposed on the substrate. The plurality of strain gauges can be configured to measure axial strains and torsional strains on the collar for measuring the one or more operational characteristics of the downhole tool.

Abstract: An electronics enclosure system includes a pressure housing with a thermally conductive material and a plurality of shells disposed within the pressure housing, wherein the plurality of shells are coupled together to form an enclosure, and wherein each shell of the plurality of shells comprises thermally conductive material. The electronics enclosure system further includes at least one circuit board secured to an inner surface of a respective shell of the plurality of shells and a plurality of electronic components secured to the at least one circuit board, the plurality of shells, or some combination thereof.

Abstract: Drill collars may be constructed using solid-state welding processes. Solid-state welding produces robust drill collars with high fatigue lifespans and permits individual segments of the drill collar to be optimized based on their intended use. A drill collar may be formed of a first segment with a different material, density, modulus of elasticity and/or geometry than an adjacent second segment fused thereto. If a segment of a drill collar is damaged in use, the damaged segment may be removed and replaced, possibly without de-rating the drill collar. Methods of forming the solid-state welds may include friction welding adjacent segments to one another such that features in each segment are circumferentially aligned when the weld is formed. Supplemental energy sources may provide additional heat at the welded surfaces to ensure the segments are effectively fused.

Abstract: A tubular string includes a first tubular member with a pin end with pin threads and a pin external load shoulder. The tubular string also includes a second tubular member with a box end with a box external load shoulder and box threads, the pin threads being threadable into the box threads to form a connection, wherein the pin external load shoulder has an outer diameter (OD) that is different than an OD of the box external load shoulder. A load distribution sleeve is locatable between the first and second tubular members when threaded together and includes a first end facing the first tubular member and a second end facing the second tubular member, wherein the ODs of the load distribution sleeve first and second ends match the ODs of the pin and box external load shoulders respectively. The load distribution sleeve contacts the pin and box external load shoulders and distributes a make-up load between the pin and box external load shoulders when the connection is made up.

Abstract: Drill collars may be constructed using solid-state welding processes. Solid-state welding produces robust drill collars with high fatigue lifespans and permits individual segments of the drill collar to be optimized based on their intended use. A drill collar may be formed of a first segment with a different material, density, modulus of elasticity and/or geometry than an adjacent second segment fused thereto. If a segment of a drill collar is damaged in use, the damaged segment may be removed and replaced, possibly without de-rating the drill collar. Methods of forming the solid-state welds may include friction welding adjacent segments to one another such that features in each segment are circumferentially aligned when the weld is formed. Supplemental energy sources may provide additional heat at the welded surfaces to ensure the segments are effectively fused.

Abstract: A tubular string includes a first tubular member with a pin end with pin threads and a pin external load shoulder. The tubular string also includes a second tubular member with a box end with a box external load shoulder and box threads, the pin threads being threadable into the box threads to form a connection, wherein the pin external load shoulder has an outer diameter (OD) that is different than an OD of the box external load shoulder. A load distribution sleeve is locatable between the first and second tubular members when threaded together and includes a first end facing the first tubular member and a second end facing the second tubular member, wherein the ODs of the load distribution sleeve first and second ends match the ODs of the pin and box external load shoulders respectively. The load distribution sleeve contacts the pin and box external load shoulders and distributes a make-up load between the pin and box external load shoulders when the connection is made up.

Abstract: Aspects of the subject technology relate to a sensor for a downhole tool. The downhole tool can include a collar and a sensor. The sensor can be secured to the collar for measuring one or more operational characteristics of the downhole tool during operation of the downhole tool. The sensor can include a substrate. The sensor can also include a plurality of strain gauges disposed on the substrate. The plurality of strain gauges can be configured to measure axial strains and torsional strains on the collar for measuring the one or more operational characteristics of the downhole tool.

Abstract: A drilling tool system includes a drilling tool collar having at least one recess and a sleeve disposed around the drilling tool collar, wherein the sleeve comprises at least one slot configured to align with the at least one recess. The drilling tool system further includes an inner key disposed within the at least one recess, an outer key secured within the at least one slot and at least partially disposed within the at least one recess, and at least one fastener configured to drive the inner key in a first lateral direction and the outer key in a second lateral direction to secure the inner key against a first lateral surface and the outer key against a second lateral surface, and wherein securing the inner key and the outer key restrains rotational movement of the sleeve with respect to the tool collar.

Abstract: A rotary steerable tool for directional drilling includes a tool body including an outer surface and a flowbore therethrough, a pad movably coupled to the tool body and alternately movable between an extended position and a retracted position, and a piston engageable with the pad to move the pad. The tool further includes a pressurized fluid supply flow path to provide fluid pressure to the piston for the piston to controllably move the pad to the extended position, and a dump valve in fluid communication with the pressurized fluid supply flow path to selectively vent fluid pressure to allow the pad to move from the extended position toward the retracted position.

Abstract: Aspects of the subject technology relate to a sensor for a downhole tool. The downhole tool can include a collar and a sensor. The sensor can be secured to the collar for measuring one or more operational characteristics of the downhole tool during operation of the downhole tool. The sensor can include a substrate. The sensor can also include a plurality of strain gauges disposed on the substrate. The plurality of strain gauges can be configured to measure axial strains and torsional strains on the collar for measuring the one or more operational characteristics of the downhole tool.

Abstract: A drilling tool system includes a drilling tool collar having at least one recess and a sleeve disposed around the drilling tool collar, wherein the sleeve comprises at least one slot configured to align with the at least one recess. The drilling tool system further includes an inner key disposed within the at least one recess, an outer key secured within the at least one slot and at least partially disposed within the at least one recess, and at least one fastener configured to drive the inner key in a first lateral direction and the outer key in a second lateral direction to secure the inner key against a first lateral surface and the outer key against a second lateral surface, and wherein securing the inner key and the outer key restrains rotational movement of the sleeve with respect to the tool collar.

Abstract: A directional drilling system includes a rotary steerable tool. The rotary steerable tool includes an extendable member configured to extend outwardly from the rotary steerable tool upon actuation, and a geolocation electronics device configured to track a position of the rotary steerable tool and the extendable member and control actuation of the extendable member. The geolocation electronics device and extendable member are configured to rotate with the rotary steerable tool.

Abstract: A drill collar having at least one pocket for receiving at least one component. The at least one pocket includes a rectangular portion that extends from a first end to a second end. The rectangular portion also includes a base surface. Each of the first and the second ends includes a transition surface extending from the base surface to a pair of shoulder surfaces and a channel. The pair of shoulder surfaces and a surface of the channel are parallel to the base surface. The channel extends to an end pocket that can be in communication with an aperture.

Abstract: Aspects of the subject technology relate to a sensor for a downhole tool. The downhole tool can include a collar and a sensor. The sensor can be secured to the collar for measuring one or more operational characteristics of the downhole tool during operation of the downhole tool. The sensor can include a substrate. The sensor can also include a plurality of strain gauges disposed on the substrate. The plurality of strain gauges can be configured to measure axial strains and torsional strains on the collar for measuring the one or more operational characteristics of the downhole tool.

Abstract: A drilling tool for use in a wellbore comprises a first collar having a first bore extending from a first send to a second end and an internal thread disposed on the bore at the second end. The drilling tool also comprises a second collar having a second bore extending from a third end to a fourth end and an external thread disposed on the third end. The third end is coupled to the second end of the first collar. A first set of components is housed within the first bore and a second set of components is housed on a sidewall of the second collar formed between the second bore and an outer surface of the second collar.