Abstract: A rotary valve with increased resistance to degradation that can include, a manifold with multiple flow paths, a rotary actuator rotatably mounted within the valve, and a valve seat that is fixedly attached to the manifold, with an end (or component) of the rotary actuator made from silicon carbide diamond (ScD) and the end having a first surface. The valve seat can have a second surface that sealingly engages the first surface. Manufacturing a rotary valve can include combining diamond particles in a press with silicon and applying temperature and pressure to produce a piece of ScD. Interposing a compound between the piece and a structure and brazing them by heating the compound between 700-1200 degrees Celsius. Forming ports and flow paths in the piece by machining the piece with an Electrical Discharge Machining (EDM) tool.

Abstract: An actuation system to control flow of a fluid includes a body including an axial cavity and a valve in fluid communication with the axial cavity, the valve including a closing member moveable into and out of a closed position against the valve seat, and a resistance member. Fluid from the axial cavity can flow through and out of the valve when the closing member is out of the closed position and the closing member is biased into or out of the closed position by a force applied by the resistance member. The closing member is movable out of or into the closed position upon a rotational speed and fluid pressure within the axial cavity being sufficient to overcome the force applied by the resistance member.

Abstract: According to aspects of the present disclosure, systems and methods for controlling the speed of a fluid-controlled drive mechanism are described herein. An example system may include a housing, a variable flow fluid pathway disposed within the housing, an electromagnet coupled to the housing, a fluid-controlled drive mechanism in fluid communication with the variable flow fluid pathway, and a load-generating assembly coupled to the fluid-controlled drive mechanism. An example method may include altering a variable flow fluid pathway disposed within a housing, wherein the variable flow fluid pathway is in fluid communication with a fluid-controlled drive mechanism, and generating an electrical current through an electromagnet, wherein the electromagnet is coupled to the housing.

Abstract: A system for controlling a downhole component within a borehole, the system including a transfer assembly coupled between a rotatable component and the downhole component, the transfer assembly including a swash plate assembly configured to control the downhole component and a member configured to engage the swash plate assembly. The member is configured to move radially based upon a rotational speed of the rotatable component to selectively engage the swash plate assembly.

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: According to aspects of the present disclosure, systems and methods for controlling the direction of a drilling assembly within a borehole are described herein. An example system may include a housing 201 b (FIG. 2B) and a variable flow fluid pathway 203 (FIG. 2B) within the housing 201b. A fluid-controlled drive mechanism 209 (FIG. 2C) may be in fluid communication with the variable flow fluid pathway 203. Additionally, an offset mandrel 212 may be coupled to an output of the fluid-controlled drive mechanism 209. The offset mandrel 212 may be independently rotatable with respect to the housing 201b. The system may also include a bit shaft 216 pivotably coupled to the housing 201b and coupled to an eccentric receptacle of the offset mandrel 212.

Abstract: Steering assemblies including a housing having an actuator positioned therein and operable to rotate a drive shaft. A planetary gearbox is positioned in the housing and includes a ring gear operatively coupled to the housing, a sun gear coupled to the drive shaft, and a planet carrier. A mechanical coupling operatively couples the ring gear to the housing such that rotation of the housing rotates the ring gear. The mechanical coupling is selected based on an ability of one or more mechanical parameters of the mechanical coupling to mitigate the stick-slip disturbance transmitted between the housing and the ring gear. An offset mandrel coupled to one of the sun gear and the planet carrier such that rotation of the one of the sun gear and the planet carrier causes the offset mandrel to correspondingly rotate, wherein the offset mandrel is independently rotatable with respect to the housing.

Abstract: A rotary steerable drilling tool and a method according to which a universal joint is sealed. In one embodiment, the method includes providing the collar, the shaft, the universal joint, and first and second shoulders between which the universal joint is positioned; providing first and second self-energizing seals between the collar and the shaft on opposite sides of the universal joint; rotating the collar and the shaft; seating the first self-energizing seal against the first shoulder; and seating a second self-energizing seal against the second shoulder. In one embodiment, the universal joint includes a convex surface formed on the shaft; a first concave surface extending circumferentially about the shaft and adapted to mate with the convex surface to carry a first axial load; and a spacer ring defining a second concave surface adapted to mate with the convex surface to carry a second axial load.

Abstract: Steering assemblies including a housing having an actuator positioned therein and operable to rotate a drive shaft. A planetary gearbox is positioned in the housing and includes a ring gear operatively coupled to the housing, a sun gear coupled to the drive shaft, and a planet carrier. A mechanical coupling operatively couples the ring gear to the housing such that rotation of the housing rotates the ring gear. The mechanical coupling is selected based on an ability of one or more mechanical parameters of the mechanical coupling to mitigate the stick-slip disturbance transmitted between the housing and the ring gear. An offset mandrel coupled to one of the sun gear and the planet carrier such that rotation of the one of the sun gear and the planet carrier causes the offset mandrel to correspondingly rotate, wherein the offset mandrel is independently rotatable with respect to the housing.

Abstract: A method for forming a controllable bend angle in a drill string in a wellbore comprises attaching an upper housing to a drill string. At least, one drive motor is anchored in the upper housing. A middle housing is operably coupled to the at least one drive motor. A lower housing is operably coupled to the at least one drive motor. The at least one drive motor is controllably operated to rotate the middle housing by a first rotation angle with respect to the upper housing, and to rotate the lower housing by a second rotation angle with respect to the upper housing, to generate a desired bend angle between the middle housing and the lower housing at a target toolface orientation between the bend angle and the upper housing.

Abstract: According to aspects of the present disclosure, systems and methods for controlling the speed of a fluid-controlled drive mechanism are described herein. An example system may include a housing, a variable flow fluid pathway disposed within the housing, an electromagnet coupled to the housing, a fluid-controlled drive mechanism in fluid communication with the variable flow fluid pathway, and a load-generating assembly coupled to the fluid-controlled drive mechanism. An example method may include altering a variable flow fluid pathway disposed within a housing, wherein the variable flow fluid pathway is in fluid communication with a fluid-controlled drive mechanism, and generating an electrical current through an electromagnet, wherein the electromagnet is coupled to the housing.

Abstract: An example method for control of a drilling assembly includes receiving measurement data from at least one sensor coupled to an element of the drilling assembly positioned in a formation. An operating constraint for at least a portion of the drilling assembly may be determined based, at least in part, on a model of the formation and a set of offset data. A control signal may be generated to alter one or more drilling parameters of the drilling assembly based, at least in part, on the measurement data and the operating constraint. The control signal may be transmitted to a controllable element of the drilling assembly.

Abstract: According to aspects of the present disclosure, systems and methods for controlling the direction of a drilling assembly within a borehole are described herein. An example system may include a housing 201 b (FIG. 2B) and a variable flow fluid pathway 203 (FIG. 2B) within the housing 201b. A fluid-controlled drive mechanism 209 (FIG. 2C) may be in fluid communication with the variable flow fluid pathway 203. Additionally, an offset mandrel 212 may be coupled to an output of the fluid-controlled drive mechanism 209. The offset mandrel 212 may be independently rotatable with respect to the housing 201b. The system may also include a bit shaft 216 pivotably coupled to the housing 201b and coupled to an eccentric receptacle of the offset mandrel 212.

Abstract: A method for forming a controllable bend angle in a drill string in a wellbore comprises attaching an upper housing to a drill string. At least, one drive motor is anchored in the upper housing. A middle housing is operably coupled to the at least one drive motor. A lower housing is operably coupled to the at least one drive motor. The at least one drive motor is controllably operated to rotate the middle housing by a first rotation angle with respect to the upper housing, and to rotate the lower housing by a second rotation angle with respect to the upper housing, to generate a desired bend angle between the middle housing and the lower housing at a target toolface orientation between the bend angle and the upper housing.

Abstract: A downhole steering tool includes distinct hydraulic and electronics modules deployed about a shaft. The hydraulics module includes a plurality of hydraulically actuated blades. The electronics module includes electronic circuitry configured to control blade actuation. The hydraulics and electronics modules are physically and electrically connected to one another via a timed connection.

Abstract: A downhole steering tool includes distinct hydraulic and electronics modules deployed about a shaft. The hydraulics module includes a plurality of hydraulically actuated blades. The electronics module includes electronic circuitry configured to control blade actuation. The hydraulics and electronics modules are physically and electrically connected to one another via a timed connection.