Dual Angle Wedge Retention System

Abstract

At least one labyrinth seal assembly is disposed within a roller cutter of a roller reamer. A first labyrinth seal assembly of a roller cutter is positioned toward a first pillow block of a cutter cartridge that includes the roller cutter. A bearing shaft of the cutter cartridge extends through an inner channel of the roller cutter. The cutter cartridge is retained in an axial recess of a tool body of the roller reamer via a compound and separate wedging of each of the two pillow blocks into a same axial recess by means of a shaped wedge particularly specialized to improve secure coupling of the assembly and reduce rattling of components. Each pillow block is rotatably coupled to the bearing shaft at an opposing end of the roller cutter.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This Nonprovisional patent application is a Continuation-in-Part Patent Application to Provisional Patent Application Ser. No. 63/290,640 as filed on Dec. 16, 2021 by Inventor Xiao Rui. Provisional Patent Application Ser. No. 63/290,640 is hereby incorporated into its entirety and for all purposes into the present disclosure.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

Not Applicable.

INCORPORATION BY REFERENCE

All publications, patents, and/or patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.

All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.

The present disclosure incorporates by reference the following US patents in their entirety and for all purposes, including: (1.) U.S. Pat. No. 10,947,786 issued on Mar. 16, 2021 to Inventor Duane Shotwell and titled ROLLER REAMER WITH MECHANICAL FACE SEAL; (2.) U.S. Pat. No. 10,837,237 issued on Nov. 17, 2020 to Inventor DUANE SHOTWELL and titled ROLLER REAMER WITH LABYRINTH SEAL ASSEMBLY; and U.S. Pat. No. 10,718,165 issued on Jul. 21, 2020 to Inventor Duane Shotwell and titled ROLLER REAMER INTEGRAL PRESSURE RELIEF ASSEMBLY.

The above-cited publications, patents, and/or patent applications are incorporated herein by reference in their entirety and for all purposes.

STATEMENT REGARDING PRIOR DISCLOSURES BY THE INVENTOR OR A JOINT INVENTOR

Not Applicable.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates generally to underground boring and, in particular, to a mounting assembly for securing a roller reamer assembly having roller cutter rotatably coupled with roller reamer tool bodies.

Background Art

The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also be inventions.

It is often necessary when drilling a borehole to maintain or enlarge the diameter of the borehole with second and subsequent passes of cutting components. This is necessary due to drill bit wear and gradual reduction in the gauge diameter of the hole. Also, certain materials being drilled can swell, which results in reduction of the borehole diameter after the drill bit has past. The technique of reaming is a significant step in achieving the required diameter of the borehole. Accordingly, there is a long-felt need for reamers presenting improved reliability, construction, and longevity, and decreased maintenance requirements.

Reamers can be used in association with a drill bit to ensure that a borehole is drilled to a constant diameter. A roller-type reamer has cutting components rotatably mounted. The roller reamer is commonly used in the drilling industry, one purpose being to ream the hole just behind the drill bit to maintain hole size. A roller reamer can also act as a stabilizer above the drill bit to stabilize the drill bit and drill string against the deviating tendencies encountered during drilling.

Roller reamer roller assemblies that include roller cutters are generally intended to be coupled with a reamer body, or tool body, while allowing the roller cutters to freely rotate about an axis that is parallel with a central axis of the tool body. One problem with roller reamers is that under the conditions commonly encountered during drilling, rock chips and other debris can build up proximate to one or more roller assemblies, which may jam or slow rotation of the roller assemblies, thereby reducing their effectiveness. Additionally, even under normal operating conditions, rotation of the roller cutters can also cause a roller assembly to increase in temperature, which further increases the stress on the rotating parts. Increased stress may cause those rotating parts to wear more quickly. This is a costly problem because the reamer will generally have to be brought to the surface, dismantled, and reassembled to replace worn-out parts.

Further, roller reamers in general are subjected to very damaging abuse and drilling conditions downhole, including extreme vibrations and shocks in lateral, axial, and torsional directions. It isn't unusual for roller reamer components to get shaken loose while downhole, and sometimes even to fall off entirely and be lost downhole. In severe cases, losing a critical component this way while operating a roller reamer may even damage the rest of the tool as well, or endanger an operator. This is a known hazard in the industry, to both the longevity of the tools and the safety of the operator; improving tool durability to reduce known and anticipatable breakdowns and facilitate safer operation will forever be an important advancement to any art.

There is therefore a long-felt need in the art to provide improvements in durability, stability, efficiency, and safe operation in the art of roller reamers for use in drilling operations. It is an object of the present invention to provide an improved assembly for the more optimal securing of roller reamers in position on the tool body.

BRIEF SUMMARY OF THE INVENTION

Towards these and other objects of the present invention (hereinafter, “the invented wedge”) that are made obvious to one of ordinary skill in the art in light of the present disclosure, an invented dual tapered wedge is provided for stabilizing a pillow block when coupled with a roller of a roller reamer.

It is noted and emphasized, particularly because images in the Figures are two-dimensional and that can make this point difficult to convey visually, that the broader-to-narrower tapering of the wedge is in multiple dimensions at once. Another way to conceptualize this is to consider that the three-dimensional wedge shape includes three pairs of opposing faces (i.e. up and down, front and back, left and right), and only one of those pairs will have both faces the same surface area; the other two pairs will have a larger face at one end tapering to a smaller face at the other.

The wedge may comprise a lower side, an upper side, a registration side and a contact side; the contact side having a substantively planar contact face, the contact face having a first edge pair and a second edge pair; the first edge pair comprising an upper edge and an opposing lower edge, the lower edge and the upper edge displaced along a Z-axis and the upper edge is positioned proximate to the upper side; the second edge pair comprising an outer edge and an opposing inner edge, the outer edge and the inner edge displaced along an X-axis, wherein the X-axis is orthogonal to the Z-axis; the contact face and the registration side are displaced along a Y-axis by a varying thickness, wherein the Z-axis, the X-axis and the Y-axis are each mutually orthogonal and the contact face is tapered in relation to the registration side along both the X-axis and the Y-axis to reduce the displacement between the contact face and the registration side, and the upper side has a greater surface area than the lower side.

In some embodiments of the invented wedge, the thickness between the contact face and the registration side increases along a positive X-axis direction extending from the outer edge to the opposing inner edge.

In some embodiments of the invented wedge, the thickness between the contact face and the registration side decreases along a positive Z-axis direction extending from the upper edge to the lower edge.

In some embodiments of the invented wedge, the thickness between the contact face and the registration side increases along the positive X-axis direction.

In some embodiments of the invented wedge, the thickness between the contact face and the registration side increases along a negative X-axis direction.

In some embodiments of the invented wedge, the thickness between the contact face and the registration side decreases in along the positive Z-axis direction.

In some embodiments of the invented wedge, the lower side is substantively planar.

In some embodiments of the invented wedge, the upper side is substantively planar.

In some embodiments of the invented wedge, the lower side is substantively planar and parallel to the upper side.

Some embodiments of the invented wedge further comprise a bolt through-hole extending fully through the wedge from the upper side and through the lower side.

Some embodiments of the invented wedge further comprise an inner side extending along the Z-axis between the upper side and the lower side and proximate to the inner edge of the contact face; an outer side extending along the Z-axis between the upper side and the lower side and proximate to the outer edge of the contact face, and wherein the bolt through-hole is equidistant from the inner side and the outer side along the X-axis.

Additionally provided herein is a retention assembly of a roller reamer, the roller reamer comprising at least a first roller rotatably coupled with a roller reamer body, the retention assembly comprising a pillow block, the pillow block fitting into a recess of the roller reamer and presenting a bottom side, a top side and a planar tapered face extending between the bottom side and the top side, the planar tapered face tapered along each of two orthogonal axes, whereby the pillow block has a maximum surface area at the bottom side; and a dual tapered wedge, the dual tapered wedge fitting into the recess of the roller reamer contemporaneously with the pillow block, wherein the dual tapered wedge presents a planar contact face for placement against the planar tapered surface, and the planar contact face is tapered along the two orthogonal axes; and the dual tapered wedge has a maximum surface area at an upper side, wherein when retention assembly is coupled with the roller reamer body the upper side is positioned proximate to the pillow block top side and distal from the pillow block bottom side.

Further, some embodiments include the pillow block comprising at least one cutter insert positioned within and extending from the pillow block top side.

Further, some embodiments include the dual tapered wedge comprising a lower side displaced from the upper side along a Z-axis, a registration side and a contact side; the contact side having a substantively planar contact face, the contact face having a first edge pair and a second edge pair; the first edge pair comprising an upper edge and an opposing lower edge, the lower edge and the upper edge displaced along the Z-axis and the upper edge is positioned proximate to the upper side; the second edge pair comprising an outer edge and an opposing inner edge, the outer edge and the inner edge displaced along an X-axis, wherein the X-axis is orthogonal to the Z-axis; the contact face and the registration side are displaced along a Y-axis by a varying thickness, wherein the Z-axis, the X-axis and the Y-axis are each mutually orthogonal and the contact face is tapered in relation to the registration side along both the X-axis and the Y-axis to reduce the displacement between the contact face and the registration side, and the upper side has a greater surface area than the lower side.

Further, some embodiments might include the dual tapered wedge lower side being substantively planar.

Further, some embodiments might include the dual tapered wedge upper side being substantively planar.

Further, some embodiments might include the dual tapered wedge lower side being substantively planar and parallel to the dual tapered wedge upper side.

Further, some embodiments might include the dual tapered wedge further comprises a bolt through-hole extending fully through the wedge from the upper side and through the lower side.

Further, in some embodiments the retention assembly further comprises a second retention module, the second retention module comprising a second pillow block, the second pillow block fitting into the recess of the roller reamer and presenting a second bottom side, a second top side and a second planar, wherein the second tapered face extend is between the second bottom side and the second top side, and the second planar tapered face is tapered along each of two orthogonal axes, whereby the second pillow block has a maximum surface area at the second bottom side; and a second dual tapered wedge, the second dual tapered wedge into the recess of the roller reamer contemporaneously with the second pillow block, wherein the second dual tapered wedge presents a second planar contact face for placement against the second planar tapered surface, and the second planar contact face is tapered along the two orthogonal axes; and the second dual tapered wedge has a maximum surface area at a second upper side, wherein when second retention assembly is coupled with the roller reamer body the second upper side is positioned proximate to the second top side and distal from the second bottom side.

Further, the retention assembly might in some embodiments include the second dual tapered wedge further comprising an additional bolt through-hole extending fully through the second dual tapered wedge from the second upper side and through the second lower side.

Additionally provided herein is a roller reamer coupled with a downhole tool body (“tool”) within a first axial recess of the tool, the roller reamer comprising a retention assembly comprising a first roller cutter, a first pillow block and a first wedge, wherein the first roller cutter is rotatably coupled with the first pillow block; the roller reamer having a central point that is located at a center of mass of the first roller cutter; the first pillow block positioned within the first axial recess and having a block top side and a planar block internal side, wherein the block top side is positioned distal from a central axis of the tool, and the planar block internal side is positioned proximate to the first wedge; the planar block internal side shaped to taper in two directions, such that the planar block internal side tapers toward the first block top side of the first pillow block as the first block planar internal side extends away from the central Z axis of the tool body, and the first planar internal side further tapers towards the center of mass of the first roller cutter; the first wedge having a wedge planar internal side positioned proximate to the planar block internal side, wherein the wedge planar internal side tapers toward the central axis of the tool, and the first wedge planar internal side further tapers away from the center point CP of the central point.

Further, some embodiments might include a threaded detachable attachment bolt, the bolt configured to extend through a wedge channel and to engage with a tool tapped receiver of the first axial recess; the tool tapped receiver extending within the tool and away from the retention assembly.

Further, some embodiments might include the first wedge further forming an empty volume positioned between the wedge channel and the tool tapped receiver, whereby the threaded detachable attachment bolt extends fully through the empty volume when the threaded detachable attachment bolt engages with the tool tapped receiver.

Further, some embodiments might include a second pillow block and a second wedge, wherein the first roller cutter is rotatably coupled with the second pillow block distal from the first pillow block; the second pillow block positioned within the first axial recess and having a second block top side and a second planar block internal side, wherein the second block top side is positioned distal from the central axis of the tool, and the second planar block internal side is positioned proximate to the second wedge; the second planar block internal side shaped to taper in two directions, such that the second planar block internal side tapers toward the second block top side of the second pillow block as the second block planar internal side extends away from the central axis of the tool body, and the second planar internal side further tapers towards the center of mass of the first roller cutter; and the second wedge having a second wedge planar internal side positioned proximate to the second planar block internal side, wherein the second wedge planar internal side tapers toward the central axis of the tool, and the second wedge planar internal side further tapers away from the center point CP of the central point.

Further, some embodiments might include a second retention assembly coupled with a second axial recess of the tool.

Further, some embodiments might include a third retention assembly coupled with a third axial recess of the tool.

Further, some embodiments might include a second retention assembly coupled with a second axial recess of the tool.

Further, some embodiments might include a third retention assembly coupled with a third axial recess of the tool.

Further, some embodiments might include a second threaded detachable attachment bolt, the second threaded detachable attachment bolt configured to extend through a second wedge channel of the second wedge and to engage with a second tool tapped receiver of the first axial recess; the second tool tapped receiver extending within the tool and away from the retention assembly.

Further, some embodiments might include the second wedge further forming a second empty volume positioned between the second wedge channel and the second tool tapped receiver, whereby the second threaded detachable attachment bolt extends fully through the second empty volume and the second threaded detachable attachment bolt engages with the second tool tapped receiver.

Further, some embodiments might include the first pillow block comprising at least one cutter insert positioned within and extending from the pillow block and away from the tool.

Further, some embodiments might include the first pillow block comprising a plurality of cutter inserts positioned within and extending from the first pillow block and away from the tool.

Additionally provided herein is a retention assembly of a roller reamer, the roller reamer comprising at least a first roller rotatably coupled with a roller reamer body, the retention assembly comprising a pillow block, the pillow block fitting into a recess of the roller reamer and presenting a bottom side, a top side and a planar tapered face extending between the bottom side and the top side, the planar tapered face tapered along each of two orthogonal axes, whereby the pillow block has a maximum surface area at the bottom side; and a dual tapered wedge, the dual tapered wedge fitting into the recess of the roller reamer contemporaneously with the pillow block, wherein the dual tapered wedge presents a wedge planar internal side for placement against the pillow block planar tapered surface, and the wedge planar internal side is tapered along the two orthogonal axes; and the dual tapered wedge having a maximum surface area at an upper side, wherein when the retention assembly is coupled with the roller reamer body the upper side is positioned proximate to the pillow block top side and distal from the pillow block bottom side.

Further, some embodiments might include the pillow block comprising at least one cutter insert positioned within and extending from the pillow block top side.

Further, some embodiments might include the dual tapered wedge further comprising a lower side displaced from the upper side along a Z-axis, an outward side, and a wedge planar internal side; the wedge planar internal side having a first edge pair and a second edge pair; the first edge pair comprising an upper edge and an opposing lower edge, the lower edge and the upper edge displaced along the Z-axis and the upper edge is positioned proximate to the upper side; the second edge pair comprising an outer edge and an opposing inner edge, the outer edge and the inner edge displaced along an X-axis, wherein the X-axis is orthogonal to the Z-axis; the wedge planar internal side and the outward side are displaced along a Y-axis by a varying thickness, wherein the Z-axis, the X-axis and the Y-axis are each mutually orthogonal and the wedge planar internal side is tapered in relation to the outward side along both the X-axis and the Y-axis to reduce the displacement between the wedge planar internal side the outward side, and the upper side has a greater surface area than the lower side.

Further, some embodiments might include the dual tapered wedge lower side being substantively planar.

Further, some embodiments might include the dual tapered wedge upper side being substantively planar.

Further, some embodiments might include the dual tapered wedge lower side being substantively planar and parallel to the dual tapered wedge upper side.

Further, some embodiments might include the dual tapered wedge further comprising a bolt through-hole extending fully through the wedge from the upper side and through the lower side.

Further, some embodiments might include the dual tapered wedge further forming an empty volume positioned between the through-hole and a tool tapped receiver, whereby a threaded detachable attachment bolt extends fully through the empty volume when the threaded detachable attachment bolt engages with the tool tapped receiver.

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

The detailed description of some embodiments of the invention is made below with reference to the accompanying figures, wherein like numerals represent corresponding parts of the figures.

FIG. 1A is a side perspective view of a first roller reamer, having three roller assemblies rotatably coupled within separate and individual axial recesses of a same tool body;

FIG. 1B is a top cut-away view of the first roller reamer having three roller assemblies rotatably coupled within separate and individual axial recesses of a tool body;

FIG. 2 is a side view of an exemplary roller assembly of FIG. 1A inserted into an exemplary axial recess of the tool body of FIG. 1A and rotatably coupled with a pair of pillow blocks of a first retention assembly;

FIG. 3 is an exploded detailed side view of the exemplary first roller assembly of FIG. 2 and elements of the cutter cartridge of FIG. 2;

FIG. 4 is a 3D image of a pillow block assembly of FIG. 2;

FIG. 5 is a 3D image of the first retention assembly of FIG. 3;

FIG. 6A is a 3D image of the first retention assembly FIG. 5 from an additional angle;

FIG. 6B is a 3D image of the first retention assembly FIG. 6A with the wedge elements detached;

FIG. 7A is a line drawing presenting the first pillow block of FIG. 6A in isolation as shown from the side;

FIG. 7B is a line drawing presenting the second pillow block of FIG. 6A in isolation as shown from the side;

FIG. 8 is a line drawing presenting the first pillow block of FIG. 7A and the second pillow block of FIG. 7B in a perspective view;

FIG. 9A is a line drawing presenting a ‘head-on’ view of the first pillow block of FIG. 7A, including where the roller of FIG. 6A couples into the first pillow block;

FIG. 9B is a line drawing presenting a ‘head-on’ view of the second pillow block of FIG. 7B, including where the roller of FIG. 6A couples into the second pillow block;

FIG. 10A is a line drawing presenting a top view of the first pillow block of FIG. 7A;

FIG. 10B is a line drawing presenting a top view of the second pillow block of FIG. 7B;

FIG. 11A is a line drawing presenting a perspective view of the second wedge and pillow block assembly of FIG. 6A;

FIG. 11B is a line drawing presenting a ‘head-on’ view of the second wedge and pillow block assembly of FIG. 11A, including where the roller of FIG. 6A couples into the second pillow block;

FIG. 11C is a line drawing presenting a rear view of the second wedge and pillow block assembly of FIG. 11A, directly opposite to the view of FIG. 11B;

FIG. 12A is a line drawing presenting a perspective view of the first wedge of FIG. 3, with sides of the wedge labeled for reference;

FIG. 12B is a line drawing presenting a contact face view of the wedge of FIG. 12A;

FIG. 12C is a line drawing presenting an upper face view along the Z axis of the wedge of FIG. 12A; and

FIG. 12D is a line drawing presenting a lower face view of the wedge of FIG. 12C;

FIG. 13A is a view of a 3D model of the wedge of FIG. 12A, presenting a perspective view which includes the outward side, planar internal side, and aperture side as labeled in FIG. 12A;

FIG. 13B is a view of the 3D model of FIG. 13A, presenting a view which includes the planar internal side and the aperture side as labeled in FIG. 12A;

FIG. 13C is a view of the 3D model of FIG. 13A, presenting a view which includes the aperture side and outward side as labeled in FIG. 12A;

FIG. 13D is a view of the 3D model of FIG. 13A, presenting a view which includes the cavity side, outward side, and planar internal side as labeled in FIG. 12A;

FIG. 13E is a view of the 3D model of FIG. 13A, presenting a view which includes the end side, outward side, and aperture side as labeled in FIG. 12A;

FIG. 13F is a view of the 3D model of FIG. 13A, presenting a view of the pillow side as labeled in FIG. 12A;

FIG. 13G is a view of the 3D model of FIG. 13A, presenting a view of the cavity side and pillow side as labeled in FIG. 12A; and

FIG. 14 is a view of the 3D model of FIG. 13C which further presents elements of a wedge coupling assembly including the wedge bolt of FIG. 3, the wedge bolt aperture of FIG. 12A, and the axial recess of FIG. 2.

DETAILED DESCRIPTION OF THE INVENTION

In the following detailed description of the invention, numerous details, examples, and embodiments of the invention are described. However, it will be clear and apparent to one skilled in the art that the invention is not limited to the embodiments set forth and that the invention can be adapted for any of several applications.

It is to be understood that this invention is not limited to particular aspects of the present invention described, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims. Methods recited herein may be carried out in any order of the recited events which is logically possible, as well as the recited order of events.

Where a range of values is provided herein, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range, is encompassed within the invention. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges and are also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the range's limits, an excluding of either or both of those included limits is also included in the invention.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, the methods and materials are now described.

It must be noted that as used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. It is further noted that the claims may be drafted to exclude any optional element. As such, this statement is intended to serve as antecedent basis for use of such exclusive terminology as “solely,” “only” and the like in connection with the recitation of claim elements, or use of a “negative” limitation.

When elements are referred to as being “connected” or “coupled,” the elements can be directly connected or coupled together or one or more intervening elements may also be present. In contrast, when elements are referred to as being “directly connected” or “directly coupled,” there are no intervening elements present.

Throughout this specification, like reference numbers signify the same elements throughout the description of the figures.

Referring now generally to the Figures particularly to FIG. 1A, FIG. 1A is a side view of a first preferred embodiment of a roller reamer 100 (hereinafter, “the first reamer” 100). The first reamer 100 includes a set of three roller assemblies 102, 104, & 106, namely a first roller assembly 102, a second roller assembly 104, and a third roller assembly 106 (not visible from this angle; see FIG. 1B), positioned radially around a central axis Z of the first reamer 100 as presented in FIG. 1B.

It is understood that the set of three roller assemblies 102, 104, & 106 are three identical instances of the same structure which differ only in their respective positions upon the surface of the first reamer 100, and anything stated herein regarding an exemplary one of the set of three roller assemblies 102, 104, & 106 applies to all of the three roller assemblies 102, 104, & 106 unless specified otherwise. Specifically, though Figures herein may present and describe a single roller assembly, that presentation and description of a selected roller assembly as a representative example, such as the first roller assembly 102, may be understood to apply to all three of the set of three roller assemblies 102, 104, & 106.

Each one of the set of three roller assemblies 102, 104, & 106 consists of a separate cutter cartridge 108 rotatably and removably coupled within a single separate and individual respective axial recesses 110A, 110B, & 110C, namely a first axial recess 110A, a second axial recess 110B, and a third axial recess 110C, all as shown in FIG. 1B, of a tool body 112. A central tool axis Z of the tool body 112 (hereinafter, “the AXIS Z”) extends centrally along an elongate dimension of the tool body 112. The cutter cartridge 108 includes a plurality of cutting inserts 114, and is further explained below. One or more of the cutting inserts of the plurality of cutting inserts 114 may be or comprise tungsten carbide, polycrystalline diamond, or other suitable abrasive material known in the art.

Each component of the first reamer 100 and/or tool body 112 may be formed from any material required by a particular application, such as a metal, alloy, composite or another material, separately or in combination. For example, each may preferably be formed from high strength steel, such as 4145H or another steel, and roller assemblies 102, 104, & 106 may preferably be formed from 1018 steel, for example. The materials used to form these components, and others, may depend on any number of factors required by a particular application, such as strength, availability, costs, or other factors, as will be understood by one of ordinary skill in the art. First reamer 100 may include other components useful for reaming a wellbore, wherein reaming may occur in any direction, including uphole, downhole or laterally.

Referring now generally to the Figures particularly to FIG. 1B, FIG. 1B presents a cutaway view as indicated by the labeled dotted line and arrows of FIG. 1A. If the tool body 112 were sheared off (without structural damage) at the indicated dotted line and a viewer were looking straight along the AXIS Z onto the cross-section revealed by the shear, FIG. 1B is an approximation of the resulting view. Each one of the set of three roller assemblies 102, 104, & 106 and their surrounding components are visible, as presented by FIG. 1A positioned around the first roller assembly 102. More particularly, each of the set of three roller assemblies 102, 104, & 106 is rotatably and removably coupled within the axial recesses 110A, 110B, & 110C of the tool body 112 respectively, and each of the set of three roller assemblies 102, 104, & 106 includes cutting inserts 114. It is noted that variation is possible, such as an embodiment which has a different number of roller assemblies than three, and the examples presented in the Detailed Description should not be construed as limiting the scope of the invention.

It is noted that the AXIS Z as previously labeled is not visible in FIG. 1B, as this would be the viewer's line of sight. Presented first in FIG. 1B are an AXIS X and an AXIS Y, such that the AXIS X is orthogonal both to the AXIS Y and to the AXIS Z; the AXIS Y is orthogonal both to the AXIS X and to the AXIS Z; and the AXIS Z is orthogonal both to the AXIS X and to the AXIS Y.

It is further noted that the remaining Figures present the first roller assembly 102 as a representative example of the set of three roller assemblies 102, 104, & 106, and the compass directions presented throughout remain consistent. It may also be useful to think of the AXIS X, as presented relative to the first roller assembly 102 specifically, as ‘toward and away from the center of the first reamer 100’, and the AXIS Y, likewise, as ‘around the circumference of the first reamer 100’, but only as presented relative to the first roller assembly 102 specifically. It is noted that in FIG. 1B, these directions, though presented orthogonally and orthogonal with respect to the first reamer 100 itself, happen to line up that way with respect to the first roller assembly 102. It is further noted that, unless the view of FIG. 1B were rotated with respect to the orthogonal compass directions, the compass directions of the other two of the set of three roller assemblies 102, 104, & 106 would be different from the compass directions presented in FIGS. 2 through 13G pertaining to the first roller assembly 102.

Referring now generally to the Figures and particularly to FIG. 2, FIG. 2 is a side view of the first roller assembly 102 of FIG. 1A, inserted into the first exemplary axial recess 110A of the tool body 112 of FIG. 1A. A pair of pillow blocks 200A & 200B, specifically a first pillow block 200A and a second pillow block 200B, are rotatably coupled with the first roller assembly 102. A first pillow block 200A is positioned at a first end 202A of the first roller assembly 102. A wedge 204, specifically a first wedge 204A, is removably coupled to the tool body 112 by a first wedge bolt 206A.

The second pillow block 200B is positioned at a second end 202B of the first roller assembly 102. A second wedge 204B is removably coupled by a second wedge bolt 206B to the tool body 112. The first wedge 204A and the second wedge 204B are sized and shaped to be respectively detachably attached by the first wedge bolt 206A and the second wedge bolt 206B to the tool body 112 to retain the pair of pillow blocks 200A & 200B and the first roller assembly 102 within the first axial recess 110A when the pair of pillow blocks 200A & 200B with the first roller assembly 102 are rotatably and detachably coupled. The first wedge 204A and the second wedge 204B are each sized and shaped to lock each respective pillow block 200A & 200B and couple the first roller assembly 102 in the axial and radial directions within the first axial recess 110A.

The first wedge 204A and second wedge 204B are considered to be a particular point of interest within the greater context established by explanation of the first reamer 100 and the first roller assembly 102. The exact optimized shape of this component, while far from being the only novel aspect of the disclosure, is considered to be relevant to a distinct improvement in reliable securing of the connected mechanical components as presented in this context. More particularly, the tapering of a wedge 204 shape as instantiated by the first wedge 204A and second wedge 204B, as well as other instances of the wedge 204 in identical assemblies elsewhere on the first reamer 100 as indicated above, is designed to mechanically reduce the shaking-loose effect of the vibrations and shocks in lateral, axial, and torsional directions that are typical to operation of a roller reamer. As mentioned above, roller reamer components being shaken loose, such that the fastenings between components loosen, components are shifted out of position, or sometimes components of a reamer are lost downhole completely, is a known problem in the art of roller reamers, which may in extreme cases become a safety hazard or damage the whole machine. The wedge 204 shape in particular as described herein is a considered to be an advancement in reducing this problem, and is therefore elaborated upon in particular detail later on.

A second plurality of cutting inserts 208 is positioned on an external side of the pillow blocks 200A & 200B, and a third plurality of cutting inserts 210 is positioned on an external side of the tool body 112. One or more of the cutting inserts of the second plurality of cutting inserts 208 or of the third plurality of cutting inserts 210 may be or comprise tungsten carbide, polycrystalline diamond, or other suitable abrasive material known in the art.

Referring now generally to the Figures particularly to FIG. 3, FIG. 3 is an exploded detailed side view of the cutter cartridge 108 of the first roller assembly 102 and elements of an exemplary first retention assembly 300. The first retention assembly 300 of the first roller assembly 102 includes the pair of pillow blocks 200A & 200B, the first wedge 204A and the second wedge 204B, a bearing shaft 302, a plurality of ball bearings 304, and two pairs of static O-ring shaft seals 306A & 306B, namely a first static O-ring shaft seal 306A and a second static O-ring shaft seal 306B. The bearing shaft 302 is fixedly coupled to the pair of pillow block 200A & 200B by pins (not shown) and is shaped form a first shaft seal groove 308A, a second shaft seal groove 308B and a shaft race 310. The first shaft seal groove 308A is sized and shaped to seat the first static O-ring shaft seal 306A and the second seal groove 308B is sized and shaped to seat the second static O-ring shaft seal 306B while a first roller cutter 312 of the first roller assembly 102 is positioned about the bearing shaft 302 and the bearing shaft 302 is coupled to the pair of pillow blocks 200A& 200B. The shaft race 310 is also sized and shaped to seat the plurality of ball bearings 304 while the first roller cutter 312 is positioned about the bearing shaft 302 and the bearing shaft 302 is coupled to the pair of pillow blocks 200A & 200B.

It is understood that a center point CP of the first roller assembly 102 is preferably located at a center of mass of the first roller cutter 312 when the first roller cutter 312 is rotatably coupled with the pillow blocks 200A & 200B.

FIG. 3 further presents an exemplary first labyrinth seal assembly 314, an exemplary second labyrinth seal assembly 316 and the first roller cutter 312. The first roller cutter 312 is comprised within the first roller assembly 102 and includes the plurality of cutting inserts 114. The bearing shaft 302 is sized and shaped to fit within the first labyrinth seal assembly 314, the second labyrinth seal assembly 316, an internal channel 318 of the first roller cutter 312 and partly within each of the pillow blocks 200A & 200B.

Referring now generally to the Figures and particularly to FIG. 4, FIG. 4 is a perspective view of a 3D model of the pillow block 200A and first wedge 204A, shown with the first roller cutter 312 not present. Also presented is a compass 400 indicating the AXIS X, AXIS Y, and AXIS Z as previously discussed.

Referring now generally to the Figures and particularly to FIG. 5, FIG. 5 is a perspective view of a 3D model of the first retention assembly 300. Labeled here to provide a frame of reference in view of other Figures which label additional aspects of this same mechanism, are the pillow block 200A, the first wedge 204A, and the first roller cutter 312.

Referring now generally to the Figures and particularly to FIG. 1A, FIG. 1B, FIG. 2, FIG. 3 and FIG. 5, a center point CP of the first retention assembly 300 is located centrally within the first retention assembly 300 along and with respect to the AXIS X, the AXIS Y, and the AXIS Z. The center point CP is also preferably positioned equidistantly between the first pillow block 200A and the second pillow block 200B when the first roller cutter 312 is coupled with the first pillow block 200A and the second pillow block 200B, and when the first retention assembly 300 is installed within the first axial recess 110A.

Referring now generally to the Figures and particularly to FIG. 6A, FIG. 6A is a second perspective view of the 3D image of FIG. 5 showing the first retention assembly 300 from an additional angle. Labeled here to provide a frame of reference in view of other Figures which label additional aspects of this same mechanism, are the pillow block 200A, the first wedge 204A, and the first roller cutter 312.

Referring now generally to the Figures and particularly to FIG. 6B, FIG. 6B is a view of the first retention assembly 300 of FIG. 6A, with the first wedge 204A and the second wedge 204B detached. Labeled here to provide a frame of reference in view of other Figures which label additional aspects of this same mechanism, are the first pillow block 200A, the second pillow block 200B, and the first roller cutter 312.

Referring now generally to the Figures and particularly to FIG. 7A, FIG. 7A is a line drawing presenting the first pillow block 200A of FIG. 6A in isolation as shown from the side.

Referring now generally to the Figures and particularly to FIG. 7B, FIG. 7B is a line drawing presenting the second pillow block 200B of FIG. 6A in isolation as shown from the side.

Referring now generally to the Figures and particularly to FIG. 8, FIG. 8 is a line drawing presenting the first pillow block of FIG. 7A and the second pillow block of FIG. 7B in a perspective view.

Referring now generally to the Figures and particularly to FIG. 1A, FIG. 1B, FIG. 2, FIG. 3, FIG. 5 and FIG. 8, when the first pillow block 200A is coupled with the first retention assembly 300 and positioned within the first axial recess 110A, a first block planar internal side 800 of the first pillow block 200A tapers toward a first block top side 802 of the first pillow block 200A as the first block planar internal side 800 extends away from the central axis Z of the tool body 112; and the first planar internal side 800 tapers towards the center point CP of the first retention assembly 300. In other words, when the first pillow block 200A is coupled with the first retention assembly 300 and positioned within the first axial recess 110A, the first block planar internal side 800 extends away from the first block top side 802 at an oblique angle relative to both the AXIS Y and the AXIS Z, and extends away from the location of center point CP in at an acute angle relative to the central axis Z.

Referring now generally to the Figures and particularly to FIG. 1A, FIG. 1B, FIG. 2, FIG. 3, FIG. 5 and FIG. 8, when the second pillow block 200B is coupled with the first roller cutter 312 and positioned within the first axial recess 110A, a second block planar internal side 804 of the second pillow block 200B tapers toward a second block top side 806 of the second pillow block 200B as the second block planar internal side 804 extends away from the central axis Z of the tool body 112; and the second planar internal side 804 tapers towards the direction of the center point CP of the first roller assembly 102. In other words, when the second pillow block 200B is coupled with the first roller assembly 102 and positioned within the first axial recess 110A, the second block planar internal side 804 extends away from the second block top side 806 at an oblique angle relative to both the AXIS Y and the AXIS Z, and extends away from the location of center point CP in at an acute angle relative to the central axis Z.

Referring now generally to the Figures and particularly to FIG. 9A, FIG. 9A is a line drawing presenting a ‘head-on’ view of the first pillow block 200A of FIG. 7A, including a first pillow block roller indentation 900A, where the first roller cutter 312 (not shown) is coupled or fitted with the first pillow block 200A.

Referring now generally to the Figures and particularly to FIG. 9B, FIG. 9B is a line drawing presenting a ‘head-on’ view of the second pillow block 200B of FIG. 7B, including a second pillow block roller indentation 900B, where the first roller cutter 312 (not shown) is coupled or fitted with the second pillow block 200B. It is noted that coupling of the first roller cutter 312 rotatably in place in the first roller assembly 102 may further include elements such as screws, bolts, fittings, or similar.

Referring now generally to the Figures and particularly to FIG. 10A, FIG. 10A is a line drawing presenting a top view of the first pillow block 200A of FIG. 7A.

Referring now generally to the Figures and particularly to FIG. 10B, FIG. 10B is a line drawing presenting a top view of the second pillow block 200B of FIG. 7B.

Referring now generally to the Figures and particularly to FIG. 11A, FIG. 11A is a line drawing presenting a perspective view of the first wedge 204A positioned relative to the first pillow block 200A of FIG. 6.

Referring now generally to the Figures and particularly to FIG. 11B, FIG. 11B is a line drawing presenting a ‘head-on’ view of the first wedge 204A positioned relative to the first pillow block 200A of FIG. 11A, including where the first roller cutter 312 of FIG. 6A couples into the first pillow block 200A within the first pillow block roller indentation 900A.

Referring now generally to the Figures and particularly to FIG. 11C, FIG. 11C is a line drawing presenting a rear view of the first wedge 204A positioned relative to first pillow block 200A of FIG. 11A, directly opposite to the view of FIG. 11B.

Referring now generally to the Figures and particularly to FIG. 1A, FIG. 1B, FIG. 2,

FIG. 3, FIG. 5, FIG. 8, FIG. 12A, and FIG. 12B, when the first wedge 204A is coupled with the first roller cutter 312 and positioned within the first axial recess 110A, a first wedge planar internal side 1200E of the first wedge 204A tapers toward the central axis Z of the tool body 112; and the first wedge planar internal side 1200E tapers away from the center point CP of the first roller assembly 102.

Referring now generally to the Figures and particularly to FIG. 12A, FIG. 12A is a line drawing presenting a perspective view of the first wedge 204A of FIG. 11A, with sides of the first wedge 204A labeled for reference and establishment of certain concepts and terminology. It is noted that FIG. 12A presents only one preferred embodiment of the first wedge 204A and the shape of this element, and should not be construed as limiting. The shape of the first wedge 204A in general is notable at least for tapering in multiple dimensions, which concept may be difficult to discern from a single angle and may require an understanding based on multiple views, as presented in FIGS. 12A through 12D and FIGS. 13A through 13G. It is understood that, while the first wedge 204A of the first roller assembly 102 is the specific instance presented and described here, the second wedge 204B of the first roller assembly 102 is another instance of the same archetype of a wedge 204, and that each of the other two of the set of three roller assemblies 102, 104, & 106 is identical to the first roller assembly 102, and therefore also include their own corresponding instances of the wedge 204.

It is noted that the wedge 204 three-dimensional shape consists, geometrically, of six sides 1200, with twelve edges 1202 where two of the sides 1200 intersect. One or more of the edges 1202 may be rounded, blunted, or beveled, as shown in the images of FIGS. 12A through 12D and FIGS. 13A through 13G. The wedge 204 may further include a bolt aperture 1204 shaped to accept a wedge bolt 206 such as the first wedge bolt 206A or the second wedge bolt 206B, and may further include a bolt cavity 1206 which is a portion of the wedge 204 shape cut out to reduce the depth of the bolt aperture 1204. It is noted that the bolt cavity 1206 does not ‘hook onto’ another assembly or accept a correspondingly shaped element. Each of the sides 1200 includes one of a plurality of planar faces 1208 (“the faces 1208”) as listed individually below. It is noted that distinction is made for the sake of thoroughness between the faces 1208, which is a narrower term specifying the planar portion of each side 1200 of the wedge 204 shape, and the sides 1200, which can be used as a broader term indicating relative location upon the wedge 204.

In this disclosure, for purposes of clarity, each of the sides 1200 of the wedge 204 shape will be named consistently, as outlined in this paragraph. The side 1200 of the wedge 204 which includes the bolt aperture 1204 is termed an APERTURE SIDE 1200A and includes an aperture side face 1208A; the side 1200 opposite the aperture side 1200A is a CAVITY SIDE 1200B and includes a cavity side face 1208B and the bolt cavity 1206. The side 1200 which faces away from an attached pillow block 200 coupled to the wedge 204, such as the first pillow block 200A in the specific case of the first wedge 204A, is termed an OUTWARD SIDE 1200C and includes an outward side face 1208C; the side 1200 opposite to the outward side is a PILLOW SIDE 1200D and includes a pillow side face 1208D, which would rest against the side of the attached pillow block 200 in an assembled state. The side 1200 which is oriented toward the first roller cutter 312 is the PLANAR INTERNAL SIDE 1200E and includes a planar internal side face 1208E; the side 1200 oriented opposite to the planar internal side 1200E (i.e. toward a distal end of the first roller cutter 312) is an END SIDE 1200F and includes an end side face 1208F.

In a preferred embodiment, the wedge 204 is tapered in multiple dimensions, such that the planar internal side face 1208E comprises a broader surface area than the end side face 1208F, and also the aperture side face 1208A comprises a broader surface area than the cavity side face 1208B. It is noted that the first wedge 204A and the second wedge 204B are mirroring shapes; the sides 1200 are named with this in mind, reflecting the position of the wedge 204 in relation to the rest of the first roller cutter 312 assembly rather than a more arbitrary ‘up, down, left, right, front, back’; the wedge 204 shape remains consistent relative to the rest of the first roller assembly 102, with each respective instance of the wedge 204 tapering in the directions of (a.) ‘away from the roller (such as the first roller cutter 312 in the context of the first roller assembly 102) and parallel to the central axis (the axis Z) of the reamer 100’ and (b.) ‘(down/in) toward the central axis (the axis Z) of the reamer 100’. The tapering directions of the first wedge 204A as presented here are further highlighted by inclusion of arrows, wherein TAPER A presents the tapering direction along the AXIS Z of ‘from broader planar internal side 1200E to narrower end side 1200F’, and TAPER B presents the tapering direction along the AXIS X of ‘from broader aperture side 1200A to narrower cavity side 1200B’.

It is noted that, if the viewer's perspective is oriented head-on toward the planar internal side 1200E of the first wedge 204A parallel to the AXIS Z, with the viewer's ‘down’ orientation toward the central axis Z of the roller reamer 100, the outward side 1200C of the first wedge 204A is on the viewer's right, whereas the mirrored shape of the second wedge 204B has the outward side 1200C to the viewer's left when viewed in the same orientation; accordingly, the images of FIGS. 12A through 12D and FIGS. 13A through 13G can be identified as depicting the first wedge 204A, as a representative instance of the wedge 204. It is noted again that, while only certain exemplary components are explained in detail, these explanations are intended to represent and apply correspondingly to other similar components, adjusting appropriately for different positioning upon the reamer 100.

Particularly regarding the edges of the end side 1200F, an end-pillow edge 1202A (the edge 1202 positioned between the end side 1200F and the pillow side 1200D) and an end-outward edge 1202B (the edge 1202 positioned between the end side 1200F and the outward side 1200C) converge toward each other; an end-aperture edge 1202C (the edge 1202 positioned between the end side 1200F and the aperture side 1200A) and an end-cavity edge 1202D (the edge 1202 positioned between the end side 1200F and the cavity side 1200B) run parallel, but the end-aperture edge 1202C is longer than the end-cavity edge 1202D. Thus, the end face 1200F is substantively trapezoidal in shape, understanding that there may be minor irregularity in shape as a result of beveling or rounding of the edges 1202.

Referring now generally to the Figures and particularly to FIG. 12B, FIG. 12B is a line drawing presenting a view of the aperture side 1200A side of the first wedge 204A of FIG. 12A. The bolt aperture 1204 is further labeled here.

Particularly regarding the edges 1202 of the aperture side 1200A, the end-aperture edge 1202C (the edge 1202 positioned between the end side 1200F and the aperture side 1200A) and a roller-aperture edge 1202E (the edge 1202 positioned between the end side 1200F and the cavity side 1200B) run parallel, but the end-aperture edge 1202C is shorter than the roller-aperture edge 1202F. An aperture-pillow edge 1202F (the edge 1202 positioned between the aperture side 1200A and the pillow side 1200D) slopes or tapers toward an opposite aperture-outward edge 1202G. Thus, the aperture face 1208A is substantively trapezoidal in shape, understanding that there may be minor irregularity in shape as a result of beveling or rounding of the edges 1202. It is further noted that a roller-outward edge 1202H may be more rounded or beveled, forming a larger corner than others of the edges 1202, and that feature is discernible from this angle; this feature can be useful also in identifying which side 1200 and/or edge 1202 is which. It is further noted that in the tapering of the pillow side 1200D toward the outward side 1200C, most if not all of the slope of that tapering may be on the pillow side 1200D. In preferred embodiment, the outward side 1200C and the planar internal side 1200E, and the roller-outward edge 1202H between these, ‘square up’ with the shape of the attached pillow block 200, as presented at least in FIGS. 6A and 6B; accordingly, the roller-outward edge 1202H may be shaped to match one of the edges of the pillow block 200 shape, rather than to match any of the other edges 1202 of the wedge 204 shape.

Referring now generally to the Figures and particularly to FIG. 12C, FIG. 12C is a line drawing presenting a view of the planar internal side 1200E side of the first wedge 204A along the AXIS Z. Particularly regarding the edges 1202 of the planar internal side 1200E, the roller-aperture edge 1202E (the edge 1202 positioned between the planar internal side 1200E and the aperture side 1200A) and a roller-cavity edge 1202I (the edge 1202 positioned between the planar internal side 1200E and the cavity side 1200B) run substantively parallel, but the roller-aperture edge 1202E is longer than the roller-cavity edge 1202I. It is noted that the aperture-outward edge 1202G may also include more bevel or slope, as visible from this angle; like the roller-outward edge 1202H, this is conforming to an overall external shape of the attached pillow block 200 as shown at least in FIGS. 6A and 6B. A roller-pillow edge 1202J (the edge 1202 positioned between the planar internal side 1200E and the pillow side 1200D) slopes or tapers toward the roller-outward edge 1202H. Thus, the planar internal side face 1200E is substantively trapezoidal in shape, understanding that there may be some irregularity in shape as a result of beveling or rounding of the edges 1202.

Referring now generally to the Figures and particularly to FIG. 12D, FIG. 12D is a line drawing presenting a view of the end side 1200F, including the end side face 1208F, of the first wedge 204A of FIG. 12A. It is noted that the edges 1202 of the end side 1200F were all visible in FIG. 12A, and accordingly, have already been enumerated and described.

Referring now generally to the Figures and particularly to FIG. 13A, FIG. 13A is an image of a three-dimensional model of the first wedge 204A of FIG. 12A. It is noted that there may be some differences in drafting style between the wedge 204 line drawings of FIGS. 12A through 12D and the wedge 204 3D models of FIGS. 13A through 13G, but while the methods of drawing are different between these media and some small differences in appearance may occur as a side effect of this, what is intended is representation of the same object, with no structural differences substantial enough for these to be described as different embodiments. Labeled here are the first wedge 204A, the aperture side 1200A including the bolt aperture 1204, the aperture-outward edge 1202G, the aperture-pillow edge 1202F, the planar internal side 1200E, the roller-pillow edge 1202J, the roller-outward edge 1202H, the pillow side 1200D, and the bolt cavity 1206.

Referring now generally to the Figures and particularly to FIG. 13B, FIG. 13B is a second view of the three-dimensional model of FIG. 13A. Labeled here are the aperture side face 1208A, the planar internal side face 1208E, the roller-outward edge 1202H, and the aperture-outward edge 1202G. It is noted that the increased beveling of the roller-outward edge 1202H and the aperture-outward edge 1202G, in conformity to the overall shape of the assembly formed when the first wedge 204A as presented here is attached to the first pillow block 200A, are readily visible from this angle.

Referring now generally to the Figures and particularly to FIG. 13C, FIG. 13C is a third view of the three-dimensional model of FIG. 13A. Labeled here are the first wedge 204A, the bolt aperture 1204, the bolt cavity 1206, the aperture side face 1208A, the outward side face 1208C, the roller-outward side 1202H, and the aperture-outward side 1202G. It is noted that, since the dimensions of tapering are from the aperture side 1200A to the cavity side 1200B and from the planar internal side 1200E to the end side 1200F, the shape of the outward side face 1208C remains substantively rectangular, with a cut-out portion for the bolt cavity 1206, and allowing for rounding due to beveling of the edges 1202.

Referring now generally to the Figures and particularly to FIG. 13D, FIG. 13D is a fourth view of the three-dimensional model of FIG. 13A. Since the cavity side face 1208B of the cavity side 1200B is divided by the bolt cavity 1206, the two parts of the cavity side face 1208B are presented here more particularly as a first cavity side face portion 1200B-1 and a second cavity side face portion 1200B-2, for the sake of thoroughness. Also labeled here are the first wedge 204, the bolt aperture 1204, the cavity side 1200B, the bolt cavity 1206, the outward side face 1208C, the roller-outward edge 1202H, the roller-cavity edge 1202I, the end-cavity edge 1202D, an outward-cavity edge 1202K (the edge 1202 positioned between the cavity side 1200B and the outward side 1200C), and a cavity-pillow edge 1202L (the edge 1202 positioned between the cavity side 1200B and the pillow side 1200D).

Referring now generally to the Figures and particularly to FIG. 13E, FIG. 13E is a fifth view of the three-dimensional model of FIG. 13A. Labeled here are the first wedge 204A, the end side 1200F, the end-outward edge 1202B, the outward side 1200C, the aperture-outward edge 1202G, the aperture side 1200A, and the bolt aperture 1204.

Referring now generally to the Figures and particularly to FIG. 13F, FIG. 13F is a sixth view of the three-dimensional model of FIG. 13A. Labeled here are the first wedge 204A, the bolt cavity 1206, and the pillow side 1200D. It is noted that, since the dimensions of tapering are from the aperture side 1200A to the cavity side 1200B and from the planar internal side 1200E to the end side 1200F, the shape of the pillow side face 1208D remains substantively rectangular, with a cut-out portion for the bolt cavity 1206, and allowing for rounding due to beveling of the edges 1202.

Referring now generally to the Figures and particularly to FIG. 13G, FIG. 13G is a seventh view of the three-dimensional model of FIG. 13A. Labeled here are the first wedge 204A, the roller-outward edge 1202H, the outward side 1200C, the cavity side 1200B, the end-cavity edge 1202D, the bolt aperture 1204, and the bolt cavity 1206. It is noted that the bolt aperture 1204 passes all the way through the aperture side face 1208A and into the bolt cavity 1206, permitting a bolt such as the first wedge bolt 206A or the second wedge bolt 206B to secure the wedge 204.

It is noted that the bolt aperture 1204 may be of any suitable size or shape to accommodate a bolt such as the first wedge bolt 206A or the second wedge bolt 206B, including variation such as the bolt aperture 1204 being smaller or larger than the bolt aperture 1204 may appear in these explanatory drawings; the bolt aperture 1204 being threaded; the bolt aperture varying in width (such as providing a broader profile proximate to the aperture side face 1208A surface for the bolt's head portion to fit into); the bolt aperture 1204 extending all the way through from the aperture side 1200A to the cavity side 1200B in embodiments which may not include the bolt cavity 1206 to shorten that aperture depth; and other such similar and obvious adaptations.

Referring now generally to the Figures and particularly to FIG. 14, FIG. 14 is a cutaway view presenting further detail regarding a detachable wedge coupling assembly 1400 comprising the first wedge bolt 206A, the bolt aperture 1204 of the first wedge 204A, and also a recess bolt aperture 1402 positioned on the surface of the first axial recess 110A proximate to the central axis Z of the reamer 100, opposite the bolt aperture 1204 when the first wedge 204A is installed in the first roller assembly 102. It is noted that this is a cutaway view for presenting elements that would otherwise be obscured from view at this angle at least by the sides of the first axial recess 110A. In preferred embodiment, a shaft 1404 of the first wedge bolt 206A traverses the wedge bolt aperture 1204 with a head 1406 of the first wedge bolt 206A unable to fit through the wedge bolt aperture 1204, the shaft 1404 passes through the wedge bolt cavity 1206, and the shaft 1406 of the first wedge bolt 206A is screwed in or otherwise secured into the recess bolt aperture 1402. It is preferred that the first wedge bolt 206A be threaded and the recess bolt aperture 1402 be tapped, to permit screwing in the first wedge bolt 206A as a method of securing. It is noted that, while the detachable wedge coupling assembly 1400 for securing the first wedge 204A is presented as the example, the same kind of assembly or similar may secure the second wedge 204B and other wedges 204 of the reamer 100. It is further noted that the detachable wedge coupling assembly 1400 may not necessarily be the only element or assembly securing the pieces of the first assembly together, or securing the first retention assembly 300 into the first axial recess 110A.

In understanding the scope of the present invention, the term “comprising” and its derivatives, as used herein, are intended to be open ended terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but do not exclude the presence of other unstated features, elements, components, groups, integers and/or steps. The foregoing also applies to words having similar meanings such as the terms, “including”, “having” and their derivatives. Also, the terms “part,” “section,” “portion,” “member” or “element” when used in the singular can have the dual meaning of a single part or a plurality of parts. Finally, terms of degree such as “substantially”, “about” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed.

While selected embodiments have been chosen to illustrate the invention, it will be apparent to those skilled in the art from this disclosure that various changes and modifications can be made herein without departing from the scope of the invention as defined in the appended claims. For example, the size, shape, location or orientation of the various components can be changed as needed and/or desired. Components that are shown directly connected or contacting each other can have intermediate structures disposed between them. The functions of one element can be performed by two, and vice versa. The structures and functions of one embodiment can be adopted in another embodiment, it is not necessary for all advantages to be present in a particular embodiment at the same time. Every feature which is unique from the prior art, alone or in combination with other features, also should be considered a separate description of further inventions by the applicant, including the structural and/or functional concepts embodied by such feature(s). Thus, the foregoing descriptions of the embodiments according to the present invention are provided for illustration only, and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.

Claims

1. A roller reamer coupled with a downhole tool body (“tool”) within a first axial recess of the tool, the roller reamer comprising:

a retention assembly comprising a first roller cutter, a first pillow block and a first wedge, wherein the first roller cutter is rotatably coupled with the first pillow block;

the roller reamer having a central point that is located at a center of mass of the first roller cutter;

the first pillow block positioned within the first axial recess and having a block top side and a planar block internal side, wherein the block top side is positioned distal from a central axis of the tool, and the planar block internal side is positioned proximate to the first wedge;

the planar block internal side shaped to taper in two directions, such that the planar block internal side tapers toward the first block top side of the first pillow block as the first block planar internal side extends away from the central Z axis of the tool body, and the first planar internal side further tapers towards the center of mass of the first roller cutter;

the first wedge having a wedge planar internal side positioned proximate to the planar block internal side, wherein the wedge planar internal side tapers toward the central axis of the tool, and the first wedge planar internal side further tapers away from the center point CP of the central point.

2. The roller reamer of claim 1, further comprising:

a threaded detachable attachment bolt, the bolt configured to extend through a wedge channel and to engage with a tool tapped receiver of the first axial recess;

the tool tapped receiver extending within the tool and away from the retention assembly.

3. The roller reamer of claim 1, the first wedge further forming an empty volume positioned between the wedge channel and the tool tapped receiver, whereby the threaded detachable attachment bolt extends fully through the empty volume when the threaded detachable attachment bolt engages with the tool tapped receiver.

4. The roller reamer of claim 1, the retention assembly further comprising:

a second pillow block and a second wedge, wherein the first roller cutter is rotatably coupled with the second pillow block distal from the first pillow block;

the second pillow block positioned within the first axial recess and having a second block top side and a second planar block internal side, wherein the second block top side is positioned distal from the central axis of the tool, and the second planar block internal side is positioned proximate to the second wedge;

the second planar block internal side shaped to taper in two directions, such that the second planar block internal side tapers toward the second block top side of the second pillow block as the second block planar internal side extends away from the central axis of the tool body, and the second planar internal side further tapers towards the center of mass of the first roller cutter; and

the second wedge having a second wedge planar internal side positioned proximate to the second planar block internal side, wherein the second wedge planar internal side tapers toward the central axis of the tool, and the second wedge planar internal side further tapers away from the center point CP of the central point.

5. The roller reamer of claim 1, further comprising a second retention assembly coupled with a second axial recess of the tool.

6. The roller reamer of claim 5, further comprising a third retention assembly coupled with a third axial recess of the tool.

7. The roller reamer of claim 4, further comprising a second retention assembly coupled with a second axial recess of the tool.

8. The roller reamer of claim 7, further comprising a third retention assembly coupled with a third axial recess of the tool.

9. The roller reamer of claim 4, further comprising:

a second threaded detachable attachment bolt, the second threaded detachable attachment bolt configured to extend through a second wedge channel of the second wedge and to engage with a second tool tapped receiver of the first axial recess;

the second tool tapped receiver extending within the tool and away from the retention assembly.

10. The roller reamer of claim 9, the second wedge further forming a second empty volume positioned between the second wedge channel and the second tool tapped receiver, whereby the second threaded detachable attachment bolt extends fully through the second empty volume and the second threaded detachable attachment bolt engages with the second tool tapped receiver.

11. The retention assembly of claim 1, wherein the first pillow block comprises at least one cutter insert positioned within and extending from the pillow block and away from the tool.

12. The retention assembly of claim 11, wherein the first pillow block comprises a plurality of cutter inserts positioned within and extending from the first pillow block and away from the tool.

13. A retention assembly of a roller reamer, the roller reamer comprising at least a first roller rotatably coupled with a roller reamer body, the retention assembly comprising:

a pillow block, the pillow block fitting into a recess of the roller reamer and presenting a bottom side, a top side and a planar tapered face extending between the bottom side and the top side, the planar tapered face tapered along each of two orthogonal axes, whereby the pillow block has a maximum surface area at the bottom side; and

a dual tapered wedge, the dual tapered wedge fitting into the recess of the roller reamer contemporaneously with the pillow block, wherein the dual tapered wedge presents a wedge planar internal side for placement against the pillow block planar tapered surface, and the wedge planar internal side is tapered along the two orthogonal axes; and

the dual tapered wedge having a maximum surface area at an upper side, wherein when the retention assembly is coupled with the roller reamer body the upper side is positioned proximate to the pillow block top side and distal from the pillow block bottom side.

14. The retention assembly of claim 13, wherein the pillow block comprises at least one cutter insert positioned within and extending from the pillow block top side.

15. The retention assembly of claim 13, wherein the dual tapered wedge further comprises:

a lower side displaced from the upper side along a Z-axis, an outward side, and a wedge planar internal side;

the wedge planar internal side having a first edge pair and a second edge pair;

the first edge pair comprising an upper edge and an opposing lower edge, the lower edge and the upper edge displaced along the Z-axis and the upper edge positioned proximate to the upper side;

the second edge pair comprising an outer edge and an opposing inner edge, the outer edge and the inner edge displaced along an X-axis, wherein the X-axis is orthogonal to the Z-axis;

the wedge planar internal side and the outward side are displaced along a Y-axis by a varying thickness, wherein the Z-axis, the X-axis and the Y-axis are each mutually orthogonal and the wedge planar internal side is tapered in relation to the outward side along both the X-axis and the Y-axis to reduce the displacement between the wedge planar internal side the outward side, and the upper side has a greater surface area than the lower side.

16. The retention assembly of claim 13, wherein the dual tapered wedge lower side is substantively planar.

17. The retention assembly of claim 13, wherein the dual tapered wedge upper side is substantively planar.

18. The retention assembly of claim 15, wherein the dual tapered wedge lower side is substantively planar and parallel to the dual tapered wedge upper side.

19. The retention assembly of claim 13, wherein the dual tapered wedge further comprises a bolt through-hole extending fully through the wedge from the upper side and through the lower side.

20. The roller reamer of claim 1, the dual tapered wedge further forming an empty volume positioned between the through-hole and a tool tapped receiver, whereby a threaded detachable attachment bolt extends fully through the empty volume when the threaded detachable attachment bolt engages with the tool tapped receiver.