UNIVERSAL COUPLING SYSTEM FOR A DRILL STRING

Abstract

A universal coupling system for a drill string is provided. The system comprises a double wedge box having a first box connection opposite a second box connection. The system also comprises a first double wedge and a second double wedge each releasably coupled to the double wedge box and each having a first wedge protrusion offset from a second wedge protrusion. The first wedge protrusion of each of the first double wedge and the second double wedge are received in the first box connection and the second box connection, respectively. The system also includes a first adaptor and a second adaptor each having a box connection opposite a pin connection. Each box connection of the first adaptor and the second adaptor receives the second wedge protrusion of each of the first and the second double wedges.

Description

FIELD OF THE INVENTION

Embodiments of the present invention generally relate to drilling with a universal coupling system, and more specifically a universal coupling system designed to allow for a universal connection between a power source and a bearing pack of a drill string or between two power sources (e.g., a dual power section) using a reduced amount of components.

BACKGROUND OF THE INVENTION

Universal coupling systems are known in the drilling arts. In particular, universal coupling systems are used to convert eccentric motion of a power source (e.g., a rotor and stator used in a mud motor) to circular motion for rotating a drill bit at a bottom of a drill string. The universal coupling system further transmits torque between the power source and the drill bit and thus must be capable of handling large amounts of torque.

Conventional coupling systems typically involve many complex components that are prone to failure and may require replacement of the entire system, causing the operator loss of operating time and increased costs. Further, conventional coupling systems may be difficult to manufacture.

SUMMARY OF THE INVENTION

These and other needs are addressed by the various embodiments and configurations of the present invention. Embodiments of this invention specifically relate to a novel system, device, and method for providing a universal coupling system having fewer components and simplified components for ease of use, manufacturing, and replacement, which saves the operator considerable time and money.

Oil and gas companies typically use a coupling system for converting eccentric motion from the power source to concentric motion at the drill-bit. Eccentric motion may cause a drill bit to drill an oversized wellbore as the drill bit may remove material in a diameter greater than a diameter of the drill bit. An oversized wellbore may cause efficiency issues during drilling as the drill bit takes more power to remove more material and/or may cause issues during casing as more cement may be needed to properly set the casing.

Thus, it is one aspect of various embodiments of the present invention to provide a universal coupling system with few components that is simple in design and thus easy to manufacture. The system in various embodiments includes a wedge rotor adaptor coupled to the power portion of a drill string. The wedge rotor adaptor includes a blank end and a box connection opposite the blank end. The box connection includes an opening for receiving a male connector, a protrusion, one end of a double wedge, or another piece in the system. The blank end can be machined to receive the specific adaptor or power portion of the drill string. The system also includes a first double wedge releasably coupled to the wedge rotor adaptor. The first double wedge includes a first wedge protrusion on a first end and a second wedge protrusion on a second end opposite the first end. The first wedge protrusion and second wedge protrusion can be the same shape, same size, and same direction/orientation; different shape and/or size; or same shape and/or size but a different direction. The first wedge protrusion is received in the opening of the box connection of the wedge rotor adaptor. The system also includes in various embodiments a double wedge box releasably coupled to the first double wedge and a second double wedge. The double wedge box includes a first box connection opposite a second box connection. Each of the first box connection and the second box connection have an opening and the opening of the first box connection receives the second wedge protrusion of the first double wedge. The system also includes in various embodiments a second double wedge releasably coupled to the double wedge box. The second double wedge has a first wedge protrusion on a first end and a second wedge protrusion on a second end opposite the first end. The first wedge protrusion and second wedge protrusion can be the same shape, same size, and same direction/orientation; different shape and/or size; or same shape and/or size but a different direction. The first wedge protrusion of the second double wedge is received in the opening of the second box connection of the double wedge box. In various embodiments, the system also includes a wedge bearing adaptor releasably coupled to the second double wedge at a first end and to the drill string (specifically the sealed bearing pack in same embodiment) at a second end opposite the first end. The wedge bearing adaptor includes a box connection opposite a pin connection. The box connection has an opening that receives the second wedge protrusion of the second double wedge. The pin connection can be a blank end in some embodiments.

Another aspect of embodiments is to provide a universal coupling system for a drill string that has a thick cross-section for absorbing high amounts of torque and/or forces. The system includes a tubular member having a first opening and a second opening, a first cavity extending inwardly into the tubular member from the first opening, and a second cavity extending inwardly into the tubular member from the second opening. The system also includes a first adaptor having an opening at a first end and a protrusion at a second end opposite the first end. In various embodiments, the system includes a first rounded base having a first wedge protrusion extending from the first rounded base in a horizontal plane and a second wedge protrusion extending from the first rounded base in an opposite direction from the first wedge protrusion and in a vertical plane substantially perpendicular to the horizontal plane, i.e., within 80° and 100° relative to each other. The rounded base can be circular, ovular, spherical, or cylindrical shaped. Each of the first wedge protrusion and the second wedge protrusion has a rounded end surface extending from a substantially flat top surface to a substantially flat bottom surface substantially parallel to the flat top surface (i.e., a curved end shape when viewed in cross-section). The first wedge protrusion is received in the first opening of the tubular member and the second wedge protrusion is received in the opening of the first adaptor. The system also includes a second adaptor having an opening at a first end and a protrusion at a second end opposite the first end. The system further includes a second rounded base having a first wedge protrusion extending from the second rounded base in a horizontal plane and a second wedge protrusion extending from the second rounded base in an opposite direction from the first wedge protrusion and in a vertical plane substantially perpendicular to the horizontal plane, i.e., within 80° and 100° relative to each other. The rounded base can be circular, ovular, spherical, or cylindrical shaped. Each of the first wedge protrusion and the second wedge protrusion has a rounded end surface extending from a substantially flat top surface to a substantially flat bottom surface parallel to the flat top surface (i.e., a curved end surface shape when viewed in cross-section). The first wedge protrusion is received in the second opening of the tubular member and the second wedge protrusion is received in the opening of the second adaptor.

In another embodiment, a universal coupling system comprises a double wedge box having a first box connection opposite a second box connection. The system also includes a first double wedge and a second double wedge each releasably coupled to the double wedge box and each having a first wedge protrusion offset from a second wedge protrusion. The first wedge protrusion of each of the first double wedge and the second double wedge are received in the first box connection and the second box connection, respectively. The system can be positioned between a bearing pack and a power source of a drill string.

In yet another embodiment, a universal coupling system for a drill string comprises a double wedge box having a first box connection opposite a second box connection. The system also comprises a first double wedge and a second double wedge each releasably coupled to the double wedge box and each having a first wedge protrusion offset from and extending in an opposite direction as a second wedge protrusion. The first wedge protrusion of each of the first double wedge and the second double wedge are received in the first box connection and the second box connection, respectively. The system also includes a first adaptor and a second adaptor each having a box connection opposite a pin connection or a blank end. Each box connection receives the second wedge protrusion of the first double wedge and the second double wedge.

In some embodiments, a universal coupling system for a drill string is provided consisting essentially of: a wedge rotor adaptor coupled to the drill string, the wedge rotor adaptor having a blank end and a box connection opposite the blank end, the box connection having an opening; a first double wedge releasably coupled to the wedge rotor adaptor, the first double wedge having a first wedge protrusion on a first end and a second wedge protrusion on a second end opposite the first end, the first wedge protrusion received in the opening of the box connection of the wedge rotor adaptor; a double wedge box releasably coupled to the first double wedge, the double wedge box having a first box connection opposite a second box connection, each of the first box connection and the second box connection having an opening, the opening of the first box connection receiving the second wedge protrusion of the first double wedge; a second double wedge releasably coupled to the double wedge box, the second double wedge having a first wedge protrusion on a first end and a second wedge protrusion on a second end opposite the first end, the first wedge protrusion received in the opening of the second box connection; and a wedge bearing adaptor releasably coupled to the second double wedge at a first end and to the drill string at a second end opposite the first end, the wedge bearing adaptor having a box connection opposite a pin connection and an opening, the opening of the box connection receiving the second wedge protrusion of the second double wedge. The universal coupling system can be used in drill strings, and specifically in down-hole mud motors.

In further embodiments, the first wedge protrusion and the second wedge protrusion of each of the first double wedge and the second double wedge are configured to move within the corresponding box connection transversely to a center axis of the drill string, thereby absorbing forces received by the drill string; and/or the first wedge protrusion and the second wedge protrusion of both the first double wedge and the second double wedge are offset approximately 90 degrees. In some embodiments, the universal coupling system further comprises retainer pins, wherein two or more of the first wedge protrusion of the first double wedge, the second wedge protrusion of the first double wedge, the first wedge protrusion of the second double wedge, and the second wedge protrusion of the second double wedge include a slot for receiving one of the retainer pins, wherein two or more of the box connection of the wedge rotor adaptor, the box connection of the wedge bearing adaptor, and the first box connection and the second box connection of the double wedge box has an aperture aligning with the corresponding slot and configured to receive the corresponding retainer pin. In various embodiments, each of the box connection of the wedge rotor adaptor and the wedge bearing adaptor and the first box connection and the second box connection of the double wedge box includes a substantially flat bottom surface or a rounded bottom surface, and each rounded bottom surface is shaped to mate with a rounded surface disposed at an end of one or more of the first wedge protrusion and the second wedge protrusion of the first double wedge and the second double wedge. In some embodiments, each of the first double wedge and the second double wedge includes a rounded base, the first wedge protrusion and the second wedge protrusion each extending from the rounded base in opposite directions. Further, each of the box connection of the wedge rotor adaptor and the wedge bearing adaptor and the first box connection and the second box connection of the double wedge box includes a rounded pocket disposed near an opening of each connection, the rounded pocket mateable with one of the rounded base of the first double wedge and the second double wedge.

In some embodiments, universal coupling system for a drill string is provided comprising: a tubular member having a first opening and a second opening, a first cavity extending inwardly into the tubular member from the first opening, and a second cavity extending inwardly into the tubular member from the second opening; a first adaptor having an opening at a first end and a protrusion at a second end opposite the first end; a first rounded base having a first wedge protrusion extending from the first rounded base in a horizontal plane and a second wedge protrusion extending from the first rounded base in an opposite direction of the first wedge protrusion in a vertical plane perpendicular to the horizontal plane, each of the first wedge protrusion and the second wedge protrusion having a rounded end surface extending from a substantially flat top surface to a bottom surface parallel to the flat top surface, the first wedge protrusion received in the first opening of the tubular member and the second wedge protrusion received in the opening of the first adaptor; a second adaptor having an opening at a first end and a protrusion at a second end opposite the first end; a second rounded base having a first wedge protrusion extending from the second rounded base in a horizontal plane and a second wedge protrusion extending from the second rounded base in an opposite direction of the first wedge protrusion in a vertical plane perpendicular to the horizontal plane, each of the first wedge protrusion and the second wedge protrusion having a rounded end surface extending from a substantially flat top surface to a bottom surface parallel to the flat top surface, the first wedge protrusion received in the second opening of the tubular member and the second wedge protrusion received in the opening of the second adaptor.

In further embodiments, each of the first wedge protrusion and the second wedge protrusion include a pair of tapered side surfaces extending between the substantially flat top surface and the bottom surface. In some embodiments, each of the first wedge protrusion and the second wedge protrusion of each of the first rounded base and the second rounded base include a slot disposed near the rounded end surface and extending through the top surface and the bottom surface for receiving a retainer pin; and/or each of the opening of the first adaptor and the second adaptor and each of the first opening and the second opening of the tubular member has an aperture aligning with the slot and configured to receive the retainer pin, thereby locking the first adaptor and the first opening of the tubular member to the first rounded base and the second adaptor and the second opening of the tubular member to the second rounded base. In various embodiments, each of the opening of the first adaptor and the second adaptor and the first opening and the second opening of the tubular member includes a bottom surface comprising a substantially flat bottom surface or a rounded bottom surface, and wherein the bottom surface comprises the rounded bottom surface and is shaped to mate with the rounded end surface of each of the first wedge protrusion and the second wedge protrusion of the first rounded base and the second rounded base.

In some embodiments, a universal coupling system for a down-hole mud motor is provided comprising: a double wedge box having a first box connection opposite a second box connection; and a first double wedge and a second double wedge each releasably coupled to the double wedge box and each having a first wedge protrusion offset from a second wedge protrusion, the first wedge protrusion of each of the first double wedge and the second double wedge being received in the first box connection and the second box connection, respectively, wherein the system is positioned between a bearing pack and a power source.

In further embodiments, each of the first double wedge and the second double wedge comprise a rectangular base having a first end and a second end, each of the first end and the second end having a spherical surface, and further wherein each of the first wedge protrusion and the second wedge protrusion extend in opposing directions from the corresponding spherical surface and are offset 90 degrees from each other, each of the first wedge protrusion and the second wedge protrusion having a substantially flat upper surface, a bottom surface parallel to the upper surface, an end surface extending between the upper surface and the bottom surface, and a slot extending through the upper surface and the bottom surface. Additionally, the double wedge box comprises: a first opening opposite a second opening, each of the first opening and the second opening having a rounded surface for receiving the corresponding spherical base, a first cavity extending into a center of the double wedge box from the first opening and receiving the first wedge protrusion or the second wedge protrusion, a second cavity extending into the center of the double wedge box from the second opening and receiving the first wedge protrusion or the second wedge protrusion, each of the first cavity and the second cavity, a first aperture extending through the double wedge box and the first cavity, a second aperture extending through the double wedge box and the second cavity, and one or more retainer pins receivable by the first aperture or the second aperture and the corresponding slot of the first wedge protrusion or the second wedge protrusion, thereby securing the first wedge protrusion or the second wedge protrusion to the double wedge box. In some embodiments, the universal coupling system further comprises a first adaptor and a second adaptor each having an opening opposite a pin connection and a cavity extending into the first adaptor and the second adaptor from the corresponding opening, each of the first adaptor and the second adaptor having an aperture extending through the first adaptor and the second adaptor and the corresponding cavity for receiving a retainer pin. In one embodiment, the first wedge protrusion and the second wedge protrusion of each of the first double wedge and the second double wedge are configured to move within the corresponding box connection along a center axis of the slot, the center axis extending along a width of the slot, thereby absorbing forces received by the drill string.

It will be appreciated by those skilled in the art that any component described in the present disclosure can be made from any strong and durable material. For example, metallic material, composite materials, ceramic materials, plastics, fiber reinforced composites or plastics, and other known materials used in the arts now or in the future. In one example, the components are manufactured from 4330 V steel and/or 4340 steel for their high strength values. It will be appreciated that all components may be manufactured from the same material or each component may be manufactured from the same or different material as each other.

The phrases “at least one”, “one or more”, and “and/or”, as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.

Unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about”.

The term “a” or “an” entity, as used herein, refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein.

The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Accordingly, the terms “including,” “comprising,” or “having” and variations thereof can be used interchangeably herein.

These and other advantages will be apparent from the disclosure of the invention(s) contained herein. The above-described embodiments, objectives, and configurations are neither complete nor exhaustive. The Summary of the Invention is neither intended nor should it be construed as being representative of the full extent and scope of the present invention. Moreover, references made herein to “the present invention” or aspects thereof should be understood to mean certain embodiments of the present invention and should not necessarily be construed as limiting all embodiments to a particular description. The present invention is set forth in various levels of detail in the Summary of the Invention as well as in the attached drawings and the Detailed Description and no limitation as to the scope of the present invention is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary of the Invention. Additional aspects of the present invention will become more readily apparent from the Detailed Description, particularly when taken together with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Those of skill in the art will recognize that the following description is merely illustrative of the principles of the invention, which may be applied in various ways to provide many different alternative embodiments. This description is made for illustrating the general principles of the teachings of this invention and is not meant to limit the inventive concepts disclosed herein.

The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description of the invention given above and the detailed description of the drawings given below, serve to explain the principles of the invention.

FIG. 1 shows a front perspective view of one embodiment of a universal coupling system;

FIG. 2 shows a cross-sectional and elevation exploded side view of the universal coupling system shown in FIG. 1;

FIG. 3A shows a top view of one embodiment of an adaptor of the universal coupling system;

FIG. 3B shows a cross-sectional view of section B-B of the adaptor of FIG. 3A;

FIG. 3C shows a cross-sectional view of section C-C of the adaptor of FIG. 3A;

FIG. 4 shows a cross-sectional view of another embodiment of an adaptor of the universal coupling system;

FIG. 5A shows a top view of one embodiment of a double wedge box of the universal coupling system;

FIG. 5B shows a cross-sectional view of section B-B of the double wedge box of FIG. 5A;

FIG. 5C shows a cross-sectional view of section C-C of the double wedge box of FIG. 5A;

FIG. 6 shows a cross-sectional view of another embodiment of a double wedge box of the universal coupling system;

FIG. 7A shows an isometric view of one embodiment of a double wedge of the universal coupling system;

FIG. 7B shows a top view of the double wedge of FIG. 7A;

FIG. 7C shows a cross-sectional view of section B-B of the double wedge of FIG. 7B; and

FIG. 8 shows a side view and partially exploded view of one embodiment of a down-hole assembly.

It should be understood that the drawings are not necessarily to scale, and various dimensions may be altered. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

DETAILED DESCRIPTION

Although the following text sets forth a detailed description of numerous different embodiments, it should be understood that the legal scope of the description is defined by the words of the claims set forth at the end of this disclosure. The Detailed Description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims. Additionally, any combination of features shown in the various figures can be used to create additional embodiments of the present invention. Thus, dimensions, aspects, and features of one embodiment can be combined with dimensions, aspects, and features of another embodiment to create the claimed embodiment.

FIGS. 1 and 2 show the main components of one embodiment of a universal coupling system 100 for use in a drill string. The system 100 comprises a double wedge box 102 coupled to a first double wedge 104 and a second double wedge 106 on opposing ends, a first adaptor 108 coupled to one of the first double wedge 104 or the second double wedge 106 and a second adaptor 110 coupled to the other one of the first double wedge 104 or the second double wedge 108. In the illustrated example, the first adaptor 108 is coupled to the first double wedge 104 and the second adaptor 110 is coupled to the second double wedge 106. In some embodiments the first adaptor 108 is coupled to a power source (e.g., a rotor, a motor, or the like) and the second adaptor 110 is coupled to a bearing pack (e.g., a sealed bearing pack). It will be appreciated that the system 100 can be oriented with either the first adaptor 108 or the second adaptor 110 upstream on the drill string. In one example, the system 100 is about 30.2″ in length, though it will be appreciated by one skilled in the art that the system 100 can be less than or greater than 30.2″ in length. In another example, the system 100 can be between about 15″ and 50″ in length. In yet another example, the system 100 can be between about 20″ and 40″ in length. In a further example, the system 100 can be between about 25″ and 35″, less than 25″ in length.

The system 100 is substantially cylindrical and each component 102, 104, 106, 108, 110 (or at least 102, 104, and 106) has the same or substantially same outer diameter as each other. In some embodiments, one or more components may have a different outer diameter than the other components. The outer diameter of the system 100 is about 3.5″ in some embodiments, though the outer diameter may be less than 3.5″ or greater than 3.5″. For example between about 3.0″ and 4.0″ or between about 2.5″ and 5.0″. The outer diameter may be sized to fit in a wellbore and/or a casing of a wellbore such that the system 100 can be delivered downhole. An outer surface of the system 100, and thus each component, is generally smooth, though in other embodiments, the outer surface of the system 100 may be coarse, textured, polished, or have any other type of surface finish. In other examples, one or more components may have a different type of surface finish than the other components. The outer surfaces can have a circular or cylindrical shape, at least when assembled.

As shown in FIG. 2, the double wedge box 102 is generally positioned in a center of the system 100. As explained in more detail below, the double wedge box 102 receives in opposing pockets a wedge of each double wedge 104, 106. A retainer pin 103 secures each double wedge 104, 106 to the double wedge box 102. The adaptors 108, 110 are disposed at opposing ends of the system 100. A pocket of each of the adaptors 108, 110 receives another wedge of each double wedge 104, 106 and a retainer pin 103 secures each double wedge 104, 106 to a corresponding adaptor 108, 110. The wedges received by the adaptors 108, 110 are offset approximately 90 degrees from the wedges received by the double wedge box 102. One or more of the retainer pins 103 may be threaded, though in other examples, the retainer pins 103 may not be threaded. In other embodiments, a portion or an entire length of the retainer pin 103 may be threaded.

Turning to FIGS. 3A, 3B, and 3C, a top view of the adaptor 108, 110 of the system 100 according to one embodiment, a cross-sectional view of section B-B of the adaptor 108, 110, and a cross-sectional view of section C-C of the adaptor 108, 110 are shown, respectively. The adaptor 108, 110 has a body 300 and a protrusion 304, together forming the adaptor length L. In the illustrated example, the adaptor 108, 110 includes a body 300 having an outer diameter OD and a body length BL. The outer diameter OD is about 3.385″ in some embodiments, though the outer diameter OD may be less than 3.385″ or greater than 3.385″. In another example, the outer diameter OD can be 0.5″ to 15″. In yet another example, the outer diameter OD can be 1.5″ to 8″. In a further example, the outer diameter OD can be 2″ to 5″. The adaptor 108, 110 has an overall length L. The length L is 9.15″ in some embodiments, though the length L may be less than 9.15″ or greater than 9.15″. In another example, the length L can be 3″ to 25″. In yet another example, the length L can be 6″ to 18″, less than 6″. In a further example, the length L can be 8″ to 12″, less than 8″. The adaptor 108, 110 also includes an opening 302 opposite a protrusion 304. As visible in FIG. 1, the body 300—but not the protrusion 304—is exposed when the system 100 is assembled and only the body length BL contributes to the overall length of the system 100.

As shown, the protrusion 304 is tapered and/or threaded T and forms a pin connection. In various examples, the thread T is a 2⅜ REG thread, though it will be appreciated that the thread T can be any size thread. In some embodiments, the protrusion 304 may not be threaded at all or may be partially threaded. In other embodiments, the protrusion 304 is a solid blank end 306, as shown in broken lines. The blank end 306 may be machined to any type of connection of any desired shape, size, and/or thread as required by the operator. The protrusion 304 as shown also includes an upper protrusion 310 having an upper protrusion diameter UPD having a diameter less than the threaded portion of the protrusion 304. The upper protrusion diameter UPD is 1.5″ in some embodiments, though the upper protrusion diameter UPD may be less than 1.5″ or greater than 1.5″. In another example, the upper protrusion diameter UPD can be 0.5″ to 5″. In yet another example, the upper protrusion diameter UPD can be 0.75″ to 3″. In a further example, the upper protrusion diameter UPD can be 1″ to 2″. The upper protrusion diameter UPD may be machined to an operator's requirement. The upper protrusion 310 may have an upper protrusion diameter UPD that decreases from the threaded portion to the end 326 such that the upper protrusion 310 tapers inward toward the end 326. In some embodiments, the end 326 is shaped as a circle when viewed from a bottom elevation view, though in other examples, the end 326 may be any shape including, but not limited to, a square, a rectangle, a hexagon, an octagon, an oval, a star, or the like. It will be appreciated by those skilled in the art that the first adaptor 108 may have a different protrusion 304 than the second adaptor 110. For example, the first adaptor 108 has a threaded pin connection while the second adaptor 110 has a blank end. In other examples, the first adaptor 108 and the second adaptor 110 have the same pin connection or the same blank end. In another example, the first adaptor 108 has a blank end and the second adaptor 110 has a pin connection. Additionally, one or both adaptors 108, 110 can have a different shape, for example a different end shape, a different taper rate, different threads, etc.

The opening 302 extends inward from an outer end surface 314 of the adaptor 108, 110. The opening 302 as shown, includes a cavity 312 inset from the outer end surface 314 of the adaptor 108, 110. In other embodiments, the opening 302 does not have a cavity. The cavity 312 includes a cavity diameter CD that is less than the adaptor 108, 110 outer diameter OD. The cavity diameter CD is 3.25″ in some embodiments, though the cavity diameter CD may be less than 3.25″ or greater than 3.25″. In another example, the cavity diameter CD can be 0.5″ to 6″. In yet another example, the cavity diameter CD can be 1.5″ to 5″. In a further example, the cavity diameter CD can be 2″ to 4″. The cavity 312 also includes a cavity surface 316 having a radius of curvature R1 that is substantially equal to or greater than a radius of curvature R2 of surfaces 702, 704 of the double wedge 104, 106, shown in FIGS. 2 and 7A. In other examples, R1 is greater than R2. The radius of curvature R1 is about 1.625″ in some embodiments, though the radius of curvature R1 may be less than 1.625″ or greater than 1.625″. In another example, the radius of curvature R1 can be 0.5″ to 3″. In yet another example, the radius of curvature R1 can be 1″ to 2″. In a further example, the radius of curvature R1 can be 1.25″ to 1.75″. In other embodiments, the cavity surface 316 is formed to any shape corresponding to the surfaces 702, 704 of the double wedge 104, 106 including, but not limited to, angular, curved, planar, boxed, or the like.

The adaptor 108, 110 also includes a pocket 318 (e.g., a female connection or a box connection) having a first pocket height PH1 and a second pocket height PH2. The first pocket height PH1 and the second pocket height PH2 are substantially similar to or greater than a first wedge height WH1 and a second wedge height WH2 of the wedge 104, 106 (shown in FIG. 7C). The first pocket height PH1 is about 2.9″ in some embodiments, though the first pocket height PH1 may be less than 2.9″ or greater than 2.9″. In another example, the first pocket height PH1 can be 0.5″ to 8″. In yet another example, the first pocket height PH1 can be 1″ to 5″. In a further example, the first pocket height PH1 can be 2″ to 4″. The second pocket height PH2 is about 2.8″ in some embodiments, though the second pocket height PH2 may be less than 2.8″ or greater than 2.8″. In another example, the second pocket height PH2 can be 0.5″ to 8″. In yet another example, the second pocket height PH2 can be 1″ to 5″. In a further example, the second pocket height PH2 can be 2″ to 4″.

The pocket 318 also includes a pocket width PW (visible in FIGS. 3A and 3C) and extends into the adaptor 108, 110 from the opening 302 at a pocket depth PD. The pocket width PW is about 1.3″ in some embodiments, though the pocket width PW may be less than 1.3″ or greater than 1.3″. In another example, the pocket width PW can be 0.5″ to 3.0″. In yet another example, the pocket width PW can be 0.75″ to 2.0″. In a further example, the pocket width PW can be 1.0″ to 1.75″. The pocket depth PD is about 3.5″ in some embodiments, though the pocket depth PD may be less than 3.5″ or greater than 3.5″. In another example, the pocket depth PD can be 0.5″ to 9.0″. In yet another example, the pocket depth PD can be 1.5″ to 7.0. In a further example, the pocket depth PD can be 2.5″ to 5″. The first pocket height PH1, second pocket height PH2, and pocket width PW are less than the cavity diameter CD.

The pocket 318 is defined by a sidewall 320 extending to a bottom surface 322 that mates with and/or is positioned adjacent to an end surface 722, 724 of the double wedge 104, 106. The bottom surface 322 may be substantially flat, i.e., substantially linear when viewed in cross-section as shown in FIG. 3B, or rounded, as shown in FIG. 4. A cross-section of the pocket 318 is generally rectangular in shape, as shown by the dashed line in FIG. 3A, though in other embodiments, the pocket 318 can be any shape including, but not limited to, square, triangular, hexagonal, circular, star, elliptical, or the like. The adaptor 108, 110 also includes an aperture 324 extending through the adapter body 300 and the pocket 318 for receiving a retaining pin (not shown) for securing the double wedge 104, 106 to the adaptor 108, 110. The center of the aperture 324 is disposed at an aperture depth AD measured from the end surface 314. The aperture depth AD is less than the pocket depth PD in the illustrated example. The aperture depth AD is about 2.75″ in some embodiments, though the aperture depth AD may be less than 2.75″ or greater than 2.75″. In another example, the aperture depth AD can be 0.5″ to 8.0″. In yet another example, the aperture depth AD can be 1″ to 6.0″. In a further example, the aperture depth AD can be 2″ to 4.0″.

FIG. 4 shows a cross-sectional view of another embodiment of the adaptor 108, 110 of the system 100. The adaptor 108, 110 is generally the same as the adaptor 108, 110 shown in FIGS. 3A-3C, except for rounded bottom surface 422. The adaptor 108, 110 has a body 300 and a protrusion 304, together forming the adaptor length L. The adaptor 108, 110 includes a body 400 having an outer diameter OD and a body length BL. The adaptor 108, 110 also includes an opening 402 extending inward from an outer end surface 414 of the adaptor 108, 110. The opening 402 as shown, includes a cavity 412 inset from the outer end surface 414 of the adaptor 108, 110. The cavity 412 also includes a cavity surface 316 having a radius of curvature R1′ that is substantially equal to a radius of curvature R2 of surfaces 702, 704 of the double wedge 104, 106, shown in FIGS. 2 and 7B. The adaptor 108, 110 also includes a pocket 418 (e.g., a female connection or a box connection) extending into the adaptor 108, 110 from the opening 402. The pocket 418 is defined by a sidewall 420 extending to a bottom surface 422 that mates with or is adjacent to an end surface 722, 724 of the double wedge 104, 106. The bottom surface 422 may be rounded and may have a radius of curvature R5 that is substantially the same as a radius of curvature R4 of end surface 722, 724 of the double wedge 104, 106, shown in FIG. 2 and FIG. 7B. Turning to FIGS. 5A, 5B, and 5C, a top view of one embodiment of the double wedge box 102 of the system 100, a cross-sectional view of section B-B of the double wedge box 102, and a cross-sectional view of section C-C of the double wedge box 102 are shown, respectively. The double wedge box 102 includes a tubular body 500 having an outer diameter OD, a length L, and a first opening 502 opposite a second opening 504. The double wedge box 102 can have a cylindrical shape (i.e., circular cross section) or other shapes when viewed in cross-section, such as ovular, square, rectangular, and other shapes. As visible in FIG. 1, the tubular body 500 along the entire length L is exposed when the system 100 is assembled and the length L of the body 500 contributes to the overall length of the system 100. The outer diameter OD is about 3.375″ in some embodiments, though the outer diameter OD may be less than 3.375″ or greater than 3.375″. In another example, the outer diameter OD can be 0.5″ to 10.0″. In yet another example, the outer diameter OD can be 1.5″ to 6.0″. In a further example, the outer diameter OD can be 2.0″ to 5.0″. The length L is about 8.0″ in some embodiments, though the length L may be less than 8.0″ or greater than 8.0″. In another example, the length L can be 2.0″ to 24.0″. In yet another example, the length L can be 5.0″ to 18.0″. In a further example, the length L can be 6.0″ to 12.0″.

Each opening 502, 504 extends inward from an outer end surface 501. Each opening 502, 504 includes a cavity 506, 508 inset from the outer end surface 501 and having a cavity surface 510, 512 and a cavity diameter CD. The cavity diameter CD is about 3.25″ in some embodiments, though the cavity diameter CD may be less than 3.25″ or greater than 3.25″. In another example, the cavity diameter CD can be 0.5″ to 6″. In yet another example, the cavity diameter CD can be 1.5″ to 5.0″. In a further example, the cavity diameter CD can be 2.0″ to 4.0″.

The cavity diameter CD is less than the double wedge box 102 outer diameter OD. In other embodiments, the first opening and the second opening do not have a cavity. The cavity surface 510, 512 has a radius of curvature R3 that is substantially equal to or greater than the radius of curvature R2 of the surface 702, 704 of the double wedge 104, 106, shown in FIGS. 2 and 7A. The radius of curvature R3 is about 1.875″ in some embodiments, though the radius of curvature R3 may be less than 1.875″ or greater than 1.875″. In another example, the radius of curvature R3 can be 0.5″ to 3.5″. In yet another example, the radius of curvature R3 can be 1.0″ to 2.5″. In a further example, the radius of curvature R3 can be 1.5″ to 2″. In other embodiments, the cavity surface 510, 512 is formed to any shape corresponding to the surface 702, 704 of the double wedge 104, 106 including, but not limited to, curved, angular, planar, boxed, or the like.

The double wedge box 102 also includes a pocket 514, 516 (e.g., a female connection or a box connection) that extends into the double wedge box 102 from each cavity 506, 508. The pocket 514, 516 has a first pocket height PH1 and a second pocket height PH2. The first pocket height PH1 and the second pocket height PH2 are substantially similar to or greater than the first wedge height WH1 and the second wedge height WH2 of the wedge 104, 106. The first pocket height PH1 is about 2.9″ in some embodiments, though the first pocket height PH1 may be less than 2.9″ or greater than 2.9″. In another example, the first pocket height PH1 can be 0.5″ to 8.0″. In yet another example, the first pocket height PH1 can be 1″ to 5.0″. In a further example, the first pocket height PH1 can be 2″ to 4″. The second pocket height PH2 is about 2.8″ in some embodiments, though the second pocket height PH2 may be less than 2.8″ or greater than 2.8″. In another example, the second pocket height PH2 can be 0.5″ to 8.0″. In yet another example, the second pocket height PH2 can be 1.0″ to 5.0″. In a further example, the second pocket height PH2 can be 2.0″ to 4.0″.

Each pocket 514, 516 also has a pocket width PW and a pocket depth PD. The pocket width PW is about 1.3″ in some embodiments, though the pocket width PW may be less than 1.3″ or greater than 1.3″. In another example, the pocket width PW can be 0.5″ to 3.0″. In yet another example, the pocket width PW can be 0.75″ to 2.0″. In a further example, the pocket width PW can be 1.0″ to 1.75″. The pocket depth PD is about 3.5″ in some embodiments, though the pocket depth PD may be less than 3.5″ or greater than 3.5″. In another example, the pocket depth PD can be 0.5″ to 9.0″. In yet another example, the pocket depth PD can be 1.5″ to 7.0″. In a further example, the pocket depth PD can be 2.5″ to 5.0″.

The first pocket height PH1, the second pocket height PH2, and the pocket width PW are less than the cavity diameter CD. In the illustrated example, each pocket 514, 516 has the same first pocket height PH1, second pocket height PH2, pocket width PW, and pocket depth PD and are aligned with each other along a center axis (i.e., longitudinal axis) 550 of the double wedge box 102. In other examples, each pocket 514, 516 has a different first pocket height PH1, second pocket height PH2, pocket width PW, and/or pocket depth PD as each other and can be offset from each other, for example, one pocket 514 may be rotated between about 45 degree and 90 degree from the other pocket 516.

Each pocket 514, 516 is defined by a sidewall 518, 520 extending to a bottom surface 522, 524 that mates with and/or is positioned adjacent to the end surface 722, 724 of the double wedge 104, 106, as will be described in further detail below. The bottom surface 522, 524 may be substantially flat, i.e., substantially linear when shown in cross-section, as shown in FIG. 5B, or rounded, as shown in FIG. 6. A cross-section of the cavity 514, 516 is generally rectangular in shape, as shown in FIG. 5A, though in other embodiments, the pocket 514, 516 can be any shape including, but not limited to, square, circular, star, elliptical, oval, triangular, hexagonal or the like.

The double wedge box 102 also includes apertures 526, 528 extending through both the body 500 and each pocket 514, 516 for receiving a retaining pin (not shown) for securing the double wedge 104, 106 to the double wedge box 102. Each aperture 526, 528 is positioned an aperture depth AD from the end surface 501, which is less than the pocket depth PD in the illustrated example. The aperture depth AD is about 2.75″ in some embodiments, though the aperture depth AD may be less than 2.75″ or greater than 2.75″. In another example, the aperture depth AD can be 0.5″ to 8.0″. In yet another example, the aperture depth AD can be 1.0″ to 6.0″. In a further example, the aperture depth AD can be 2.0″ to 4.0″.

In various embodiments an outer surface 530 of the body 500 may have a smooth surface finish, though in other embodiments, the outer surface 530 of the body 500 may have any type of surface finish including, but not limited to, rough, textured, polished, or the like. Additionally, the body 500 has the same outer diameter OD along the length L of the body 500. In other embodiments, the outer surface 530 of the body has one or more different outer diameters ODs along the length L of the body 500.

FIG. 6 shows a cross-sectional view of another embodiment of the double wedge box 102 of the system 100. The double wedge box 102 of FIG. 6 is generally the same as the double wedge box 102 shown in FIGS. 5A-5C, except for rounded end surface 622, 624. The double wedge box 102 includes a tubular body 600 having an outer diameter OD, a length L, and a first opening 602 opposite a second opening 604. Each opening 602, 604 includes a cavity 606, 608 having a cavity surface 610, 612 with a radius of curvature R3′ that is substantially equal to the radius of curvature R2 of the surfaces 702, 704 of the double wedge 104, 106, shown in FIGS. 2 and 7A. The double wedge box 102 also includes a pocket 614, 616 (e.g., a female connection or a box connection) that extends into the double wedge box 102 from the first opening 602 and the second opening 604, respectively. Each pocket 614, 616 is defined by a sidewall 618, 620 extending to a bottom surface 622, 624 that mates with and/or is positioned adjacent to the end surface 722, 724 of the double wedge 104, 106. The bottom surface 622, 624 may be rounded and may have a radius of curvature R7 that is substantially the same as a radius of curvature R4 of end surface 722, 724 of the double wedge 104, 106, shown in FIGS. 2 and 7B.

Turning to FIGS. 7A, 7B, and 7C, an isometric view of one embodiment of the double wedge 104, 106 of the system 100, a top view of the double wedge 104, 106, and a cross-sectional view of section B-B of the double wedge 104, 106 are shown, respectively. The double wedge 104, 106 has an overall length L, a base 700 having a base length BL, a base diameter BD, and the pair of surfaces 702, 704 extending in opposing directions from the base 700.

The length L is about 9.0″ in some embodiments, though the length L may be less than 9.0″ or greater than 9.0″. In another example, the length L can be 2.0″ to 18.0″. In yet another example, the length L can be 5.0″ to 15″. In a further example, the length L can be 7.0″ to 12.0″. The base length BL is 2″ in some embodiments, though the base length BL may be less than 2″ or greater than 2″. In another example, the base length BL can be 0.5″ to 7.0″. In yet another example, base length BL can be 1.0″ to 5.0″. In a further example, the base length BL can be 1.5″ to 3.0″. The base diameter BD is about 3.375″ in some embodiments, though the base diameter BD may be less than 3.375″ or greater than 3.375″. In another example, the base diameter BD can be 0.5″ to 9.0″. In yet another example, the base diameter BD can be 1.0″ to 7.0″. In a further example, the base diameter BD can be 3.0″ to 4.0″.

In the illustrated example, the base 700 is cylindrical and appears rectangular in cross-section, though in other examples, the base 700 can be any shape including, but not limited to, conical, square, oval, spherical, triangular, or the like. The base 700 includes surface 703 that is perpendicular to an outer surface 709 of the base 700. The surface 703 is substantially flat or planar and is matable with and/or positioned adjacent to end surfaces 314, 501 of the adaptor 108, 110 or the double wedge box 102. As is visible in FIG. 1, the base 700 is exposed when the system 100 is assembled and only the base length BL contributes to the overall length of the system 100.

In the illustrated example, the pair of surfaces 702, 704 have an outer diameter OD proximate the surface 703, which is substantially the same as the cavity diameter CD of the adaptor 108, 110 and the double wedge box 102. The outer diameter OD is about 3.25″ in some embodiments, though the outer diameter OD may be less than 3.25″ or greater than 3.25″. In another example, the outer diameter OD can be 0.5″ to 6.0″. In yet another example, the cavity diameter CD can be 1.5″ to 5.0″. In a further example, the cavity diameter CD can be 2.0″ to 4.0″.

The surfaces 702, 704 are also rounded and have the radius of curvature R2, though in other examples, the surfaces 702, 704 can be any shape including, but not limited to, planar, faceted, angled, or boxed. The radius of curvature R2 is about 1.63″ in some embodiments, though the radius of curvature R2 may be less than 1.63″ or greater than 1.63″. In another example, the radius of curvature R2 can be 0.5″ to 3.0″. In yet another example, the radius of curvature R2 can be 1.0″ to 2.0″. In a further example, the radius of curvature R2 can be 1.25″ to 1.75″. The surfaces 702, 704 mate with the corresponding pocket surfaces 316, 510, 512 of the adaptor 108, 110 and double wedge box 102, as previously described. This mating relationship provides more stability between the double wedge 104, 106 and the adaptor 108, 110 and double wedge box 102. In some examples, the rounded shape of the surface 702, 704 and the corresponding pocket surface 316, 510, 512 are mateable and allow the double wedge 104, 106 to rotate within the cavity 312, 506, 508 when a protrusion 708, 710 of the double wedge 104, 106 moves along a slot 726, 728, as described in more detail below.

The double wedge 104, 106 also includes the first wedge protrusion 708 and the second wedge protrusion 710 (e.g., male connectors) extending from the surfaces 702, 704, respectively, in opposing directions. In the illustrated example, the first wedge protrusion 708 and the second wedge protrusion 710 are offset about 90 degrees from each other, or between 80° and 100° from each other. Explained differently, the first wedge protrusion 708 extends in a first plane and the second wedge protrusion 710 extends in a second plane that is substantially perpendicular to the first plane. In the same example, the first plane may be oriented in a left-to-right direction and the second plane may be oriented in a front-to-back or up-to-down direction when viewing a cross-section of the wellbore. It will be appreciated by those skilled in the art that during use, each wedge protrusion 708, 710 will change orientations as the drill string rotates such that either wedge protrusion 708, 710 may be oriented in the left-to-right direction, the front-to-back direction, or between.

Each wedge protrusion 708, 710 includes an upper surface 712 substantially parallel to and opposite a bottom surface 714. An angle formed between the upper surface 712 and the bottom surface 714 is between −5° and 5°. Each of the upper surface 712 and the bottom surface 714 are substantially flat or planar and are separated a distance forming a wedge width WW. The wedge width WW is about 1.25″ in some embodiments, though the wedge width WW may be less than 1.25″ or greater than 1.25″. In another example, the wedge width WW can be 0.5″ to 4.0″. In yet another example, the wedge width WW can be 0.75″ to 3.0″. In a further example, the wedge width WW can be 1.0″ to 2″.

Each of the upper surface 712 and the bottom surface 714 also extend from the surface 702, 704 at a distance forming a wedge depth WD and span a distance forming a first wedge height WH1 at the surface 702, 704, and a second wedge height WH2 at an end surface 722, 724 and a third wedge height WH3 between WH1 and WH2. The third height WH3 extends across the upper surface 712 and the bottom surface 714 before the surfaces 712, 714 curve at side surfaces 718, 720. The second wedge height WH2 is less than the first wedge height WH1, as shown in FIG. 7A, because each wedge protrusion 708, 710 tapers at a wedge angle WA from the 702, 704 to end surfaces 722, 724. In one example, the wedge angle WA is about 1.5 degrees, though it will be appreciated by one skilled in the art that the wedge angle WA can be less than or greater than 1.5 degrees. In another example, the wedge angle WA can be 0.5 degrees to 5.0 degrees. In yet another example, the wedge angle WA can be 0.75 degrees to 3.0 degrees. In a further example, the wedge angle WA can be 1.0 degree to 2.0 degrees.

The wedge depth WD is about 3.25″ in some embodiments, though the wedge depth WD may be less than 3.25″ or greater than 3.25″. In another example, the wedge depth WD can be 0.5″ to 9.0″. In yet another example, the wedge depth WD can be 1.0″ to 6.0″. In a further example, the wedge depth WD can be 3.0″ to 4.0″. The first wedge height WH1 is about 2.9″ in some embodiments, though the first wedge height WH1 may be less than 2.9″ or greater than 2.9″. In another example, the first wedge height WH1 can be 0.5″ to 9.0″. In yet another example, the first wedge height WH1 can be 1.0″ to 6.0″. In a further example, the first wedge height WH1 can be 2.0″ to 3.5″. The second wedge height WH2 is about 2.75″ in some embodiments, though the second wedge height WH2 may be less than 2.75″ or greater than 2.75″. In another example, the second wedge height WH2 can be 0.5″ to 8.0″. In yet another example, the second wedge height WH2 can be 1.0″ to 6.0″. In a further example, the second wedge height WH2 can be 2.0″ to 3.5″. The third wedge height WH3 is about 2.825″ in some embodiments, though the third wedge height WH3 may be less than 2.825″ or greater than 2.825″. In another example, the third wedge height WH3 can be 0.5″ to 7.0″. In yet another example, the third wedge height WH3 can be 1.0″ to 6.0″. In a further example, the third wedge height WH3 can be 2.0″ to 3.5″.

Each wedge protrusion 708, 710 has the side surfaces 718, 720 opposite one another and forming the first wedge height WH1, the second wedge height WH2, and the third wedge height WH3. The side surface 718, 720 can be substantially flat or planar or can be curved as shown in FIGS. 7A and 7B. The curves of side surfaces 718, 720 form the different wedge heights, i.e., the difference between the first wedge height WH1 and the third wedge height WH3. The side surfaces 718, 720 extend between and connect the upper surface 712 and bottom surface 714. The wedge width WW, first wedge height WH1, third wedge height WH3, and wedge depth WD are substantially similar to or less than the pocket width PW, first pocket height PH1, second pocket height PH2, and pocket depth PD, respectively, of the adaptor 108, 110 and the double box connection 102 such that the protrusions 708, 710 are receivable in the corresponding pockets 318, 514, 516 of the adaptor 108, 110 or the double box connection 102.

Each wedge protrusion 708, 710 also includes the end surface 722, 724 extending between the upper surface 712 and the bottom surface 714, extending between the side surfaces 718, 720, and disposed at the end of the wedge protrusion 708, 710. Each end surface 722, 724 is matable with and/or positioned adjacent to a corresponding bottom surface 322, 422, 522, 524, 622 of the adaptor 108, 110 or the double box connection 102 as previously described above. In the illustrated example, the end surfaces 722, 724 are rounded in both the width direction (i.e., wedge width WW) and height direction (i.e., wedge height WH) and have a radius of curvature R4. The radius of curvature R4 is about 1.59″ in some embodiments, though the radius of curvature R4 may be less than 1.59″ or greater than 1.59″. In another example, the radius of curvature R4 can be 0.5″ to 3″. In yet another example, the radius of curvature R4 can be 1″ to 2″. In a further example, the radius of curvature R4 can be 1.25″ to 1.75″. The radius of curvature R4 may be the same as or slightly smaller than radius of curvature R5 of the adaptor 108, 110 or radius of curvature R7 of the double box connection 102. In other examples, the end surface 722, 724 can be substantially flat or planar in either or both the height and width directions.

The protrusion 708, 710 may further include the wedge angle WA wherein the side surface 718, 570 may taper from the surface 704 to the end surface 724. The wedge angle WA is measured from a horizontal line perpendicular to a transverse axis 701 and the horizontal line is parallel to a longitudinal axis (not shown). Such wedge angle WA may allow for the double wedge 104, 106 to rotate within the pocket 318, 418, 514, 516, 614, 616 of the adaptor 108, 110 or the double wedge box 102 when the protrusion 708, 710 of the double wedge 104, 106 moves along a slot 726, 728, as described in more detail below.

The double wedge 104, 106 also includes a slot 726, 728 disposed on each of the first wedge protrusion 708 and the second wedge protrusion 710. It will be appreciated that each double wedge 104, 106 may have one slot, less than one slot, or more than one slot. The slots 726, 728 are generally rounded rectangular shaped, as shown in the illustrated example, though one or both slots 726, 728 can be other shapes including, but not limited to, an oval, a circle, a triangle, a square, a rectangle, or the like. The slot 726, 728 extends through the upper surface 712 and the bottom surface 714 and includes a slot length SL and a slot width SW.

The slot length SL is about 1.0″ in some embodiments, though the slot length SL may be less than 1.0″ or greater than 1.0″. In another example, the slot length SL can be 0.25″ to 3.0″. In yet another example, the slot length SL can be 0.5″ to 2.5″. In a further example, the slot length SL can be 0.75″ to 1.5″. The slot width SW is about 0.5″ in some embodiments, though the slot width SW may be less than 0.5″ or greater than 0.5″. In another example, the slot width SW can be 0.1″ to 2.0″. In yet another example, the slot width SW can be 0.25″ to 1.0″. In a further example, the slot width SW can be 0.4″ to 0.7″.

Each slot 726, 728 can be a different shape and/or size from each other. When the wedge protrusion 708, 710 is received in a corresponding pocket 318, 418, 514, 516, 614, 616 and the retainer pin 103 is disposed in the slot 726, 728 of the wedge protrusion 708, 710 and the corresponding aperture 324, 526, 528 of the adaptor 108, 110 or the double box connection 102, the wedge protrusion 708, 710 is secured to the corresponding double wedge box 102 or adaptor 108, 110. In various embodiments, the slot width SW is substantially similar to a diameter of a retaining pin. The slot width SW is smaller than the slot length SL, thereby allowing for movement of the double wedge 104, 106 along the slot length SL. In other words, the double wedge 104, 106 can move transverse to the center axis (longitudinal axis) 550 of the double wedge box 102 or adaptor 108, 110. In other embodiments, the retaining pin can move along the slot length SL or both the retaining pin and the double wedge 104, 106 can move along the slot length SL. Further, in various embodiments, the wedge angle WA and the surfaces 702, 704 being rounded allow for rotational movement of the double wedge 104, 106 in combination with the transverse movement along the slot length SL. Movement of the double wedge 104, 106 allows for the system 100 to absorb forces received by the drill string, thereby relieving forces from the power source and/or other components that may be more fragile (e.g., sensors, the rotor, or the like).

During use, the components are assembled together as shown and described in FIGS. 1 and 2 and the universal coupling system 100 may be assembled as part of a down-hole assembly 800 (e.g., a bottom hole assembly) shown in FIG. 8. The down-hole assembly 800 as illustrated includes a drill bit 802 disposed at a bottom end of the down-hole assembly 800, coupled to a sealed bearing pack 804, which is connected to a bearing adaptor 806. The bearing adaptor 806 is connected to the universal coupling system 100, which is connected to the power section 810 of the down-hole assembly 800. The bearing adaptor 806 is coupled to one of the adaptors 108, 110 and another one of the adaptors 108, 110 is coupled to a rotor or other motor 810 of a mud motor. U.S. Pat. No. 9,850,709, which is incorporated by reference in its entirety, describes an example sealed bearing pack 804 and example mud motor that may be used in the down-hole assembly. In other embodiments, the down-hole assembly 800 may include more components or less components than shown in FIG. 8. Further, in other embodiments, the universal coupling system 100 may be coupled to components other than the motor 810 and/or the bearing adaptor 806.

The outer diameter OD of each of the adaptors 108, 110, the double wedges 108, 110, and the double wedge box 102 are substantially the same and flush with each other. In the illustrated example of FIG. 8, the outer diameter OD of each of the adaptors 108, 110, the double wedges 108, 110, and the double wedge box 102 are substantially the same as an outer diameter of a housing of the sealed bearing pack 804 and/or a housing of the motor 810.

In the illustrated example of FIGS. 1 and 2, four retaining pins would be needed to secure the first wedge adaptor 104 to the double wedge box 102 and the first adaptor 108 and the second wedge adaptor 106 to the double wedge box 102 and the second adaptor 110. Though one skilled in the art would understand that less than four retaining pins or more than four retaining pins may be used to assemble the system 100. The system 100 is simple to assemble, as the wedge protrusion 722, 724 is received into a corresponding pocket 318, 418, 514, 516, 614, 616 of the adaptor 108, 110 or the double box connection 102 and a retainer pin 103 is inserted into a corresponding aperture 324, 526, 528 and slot 726, 728. This is advantageous if a component requires replacement as assembly and disassembly of the system 100 are easy and quick to perform. Further, the entire system 100 will not need to be replaced.

The system 100 can be assembled prior to transportation to a drilling site or can be assembled at the drilling site. The overall length of the system 100, as previously described, is generally about 30″ or between 15″ and 50″, makes the system 100 convenient to ship. Further, each component is designed for ease of manufacturing as the geometries are simple to machine. Additionally, each component has a thick cross-section of material, resulting in a component with a high amount of strength that can receive a high amount of force without failing. The system 100 also has few working components, and thus, few components capable of failure and few components to replace if needed.

While various embodiments of the present invention have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the following claims. Further, the invention(s) described herein is capable of other embodiments and of being practiced or of being carried out in various ways. It is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

Claims

1. A universal coupling system for a drill string consisting essentially of:

a wedge rotor adaptor coupled to the drill string, the wedge rotor adaptor having a blank end and a box connection opposite the blank end, the box connection having an opening;

a first double wedge releasably coupled to the wedge rotor adaptor, the first double wedge having a first wedge protrusion on a first end and a second wedge protrusion on a second end opposite the first end, the first wedge protrusion received in the opening of the box connection of the wedge rotor adaptor;

a double wedge box releasably coupled to the first double wedge, the double wedge box having a first box connection opposite a second box connection, each of the first box connection and the second box connection having an opening, the opening of the first box connection receiving the second wedge protrusion of the first double wedge;

a second double wedge releasably coupled to the double wedge box, the second double wedge having a first wedge protrusion on a first end and a second wedge protrusion on a second end opposite the first end, the first wedge protrusion received in the opening of the second box connection; and

a wedge bearing adaptor releasably coupled to the second double wedge at a first end and to the drill string at a second end opposite the first end, the wedge bearing adaptor having a box connection opposite a pin connection and an opening, the opening of the box connection receiving the second wedge protrusion of the second double wedge.

2. The universal coupling system of claim 1, wherein the first wedge protrusion and the second wedge protrusion of each of the first double wedge and the second double wedge are configured to move within the corresponding box connection transversely to a center axis of the drill string, thereby absorbing forces received by the drill string.

3. The universal coupling system of claim 1, wherein the first wedge protrusion and the second wedge protrusion of both the first double wedge and the second double wedge are offset approximately 90 degrees.

4. The universal coupling system of claim 1, further comprising retainer pins, wherein two or more of the first wedge protrusion of the first double wedge, the second wedge protrusion of the first double wedge, the first wedge protrusion of the second double wedge, and the second wedge protrusion of the second double wedge include a slot for receiving one of the retainer pins.

5. The universal coupling system of claim 4, wherein two or more of the box connection of the wedge rotor adaptor, the box connection of the wedge bearing adaptor, and the first box connection and the second box connection of the double wedge box has an aperture aligning with the corresponding slot and configured to receive the corresponding retainer pin.

6. The universal coupling system of claim 1, wherein each of the box connection of the wedge rotor adaptor and the wedge bearing adaptor and the first box connection and the second box connection of the double wedge box includes a substantially flat bottom surface or a rounded bottom surface.

7. The universal coupling system of claim 6, wherein each rounded bottom surface is shaped to mate with a rounded surface disposed at an end of one or more of the first wedge protrusion and the second wedge protrusion of the first double wedge and the second double wedge.

8. The universal coupling system of claim 1, wherein each of the first double wedge and the second double wedge includes a rounded base, the first wedge protrusion and the second wedge protrusion each extending from the rounded base in opposite directions.

9. The universal coupling system of claim 8, wherein each of the box connection of the wedge rotor adaptor and the wedge bearing adaptor and the first box connection and the second box connection of the double wedge box includes a rounded pocket disposed near an opening of each connection, the rounded pocket mateable with one of the rounded base of the first double wedge and the second double wedge.

10. A universal coupling system for a drill string comprising:

a tubular member having a first opening and a second opening, a first cavity extending inwardly into the tubular member from the first opening, and a second cavity extending inwardly into the tubular member from the second opening;

a first adaptor having an opening at a first end and a protrusion at a second end opposite the first end;

a first rounded base having a first wedge protrusion extending from the first rounded base in a horizontal plane and a second wedge protrusion extending from the first rounded base in an opposite direction of the first wedge protrusion in a vertical plane perpendicular to the horizontal plane, each of the first wedge protrusion and the second wedge protrusion having a rounded end surface extending from a substantially flat top surface to a bottom surface parallel to the flat top surface, the first wedge protrusion received in the first opening of the tubular member and the second wedge protrusion received in the opening of the first adaptor;

a second adaptor having an opening at a first end and a protrusion at a second end opposite the first end;

a second rounded base having a first wedge protrusion extending from the second rounded base in a horizontal plane and a second wedge protrusion extending from the second rounded base in an opposite direction of the first wedge protrusion in a vertical plane perpendicular to the horizontal plane, each of the first wedge protrusion and the second wedge protrusion having a rounded end surface extending from a substantially flat top surface to a bottom surface parallel to the flat top surface, the first wedge protrusion received in the second opening of the tubular member and the second wedge protrusion received in the opening of the second adaptor.

11. The universal coupling system of claim 10, wherein each of the first wedge protrusion and the second wedge protrusion include a pair of tapered side surfaces extending between the substantially flat top surface and the bottom surface.

12. The universal coupling system of claim 10, wherein each of the first wedge protrusion and the second wedge protrusion of each of the first rounded base and the second rounded base include a slot disposed near the rounded end surface and extending through the top surface and the bottom surface for receiving a retainer pin.

13. The universal coupling system of claim 12, wherein each of the opening of the first adaptor and the second adaptor and each of the first opening and the second opening of the tubular member has an aperture aligning with the slot and configured to receive the retainer pin, thereby locking the first adaptor and the first opening of the tubular member to the first rounded base and the second adaptor and the second opening of the tubular member to the second rounded base.

14. The universal coupling system of claim 10, wherein each of the opening of the first adaptor and the second adaptor and the first opening and the second opening of the tubular member includes a bottom surface comprising a substantially flat bottom surface or a rounded bottom surface.

15. The universal coupling system of claim 14, wherein the bottom surface comprises the rounded bottom surface and is shaped to mate with the rounded end surface of each of the first wedge protrusion and the second wedge protrusion of the first rounded base and the second rounded base.

16. A universal coupling system for a down-hole mud motor comprising:

a double wedge box having a first box connection opposite a second box connection; and a first double wedge and a second double wedge each releasably coupled to the double wedge box and each having a first wedge protrusion offset from a second wedge protrusion, the first wedge protrusion of each of the first double wedge and the second double wedge being received in the first box connection and the second box connection, respectively,

wherein the system is positioned between a bearing pack and a power source.

17. The universal coupling system of claim 16, wherein each of the first double wedge and the second double wedge comprise a rectangular base having a first end and a second end, each of the first end and the second end having a spherical surface, and further wherein each of the first wedge protrusion and the second wedge protrusion extend in opposing directions from the corresponding spherical surface and are offset 90 degrees from each other, each of the first wedge protrusion and the second wedge protrusion having a substantially flat upper surface, a bottom surface parallel to the upper surface, an end surface extending between the upper surface and the bottom surface, and a slot extending through the upper surface and the bottom surface.

18. The universal coupling system of claim 17, wherein the double wedge box comprises:

a first opening opposite a second opening, each of the first opening and the second opening having a rounded surface for receiving the corresponding spherical base,

a first cavity extending into a center of the double wedge box from the first opening and receiving the first wedge protrusion or the second wedge protrusion,

a second cavity extending into the center of the double wedge box from the second opening and receiving the first wedge protrusion or the second wedge protrusion, each of the first cavity and the second cavity,

a first aperture extending through the double wedge box and the first cavity,

a second aperture extending through the double wedge box and the second cavity, and

one or more retainer pins receivable by the first aperture or the second aperture and the corresponding slot of the first wedge protrusion or the second wedge protrusion, thereby securing the first wedge protrusion or the second wedge protrusion to the double wedge box.

19. The universal coupling system of claim 16, further comprising a first adaptor and a second adaptor each having an opening opposite a pin connection and a cavity extending into the first adaptor and the second adaptor from the corresponding opening, each of the first adaptor and the second adaptor having an aperture extending through the first adaptor and the second adaptor and the corresponding cavity for receiving a retainer pin.

20. The universal coupling system of claim 16, wherein the first wedge protrusion and the second wedge protrusion of each of the first double wedge and the second double wedge are configured to move within the corresponding box connection along a center axis of the slot, the center axis extending along a width of the slot, thereby absorbing forces received by the drill string.