Abstract:
In one aspect of the invention, a downhole tool string component has at least one end adapted to connect to an adjacent tool sting component and a bore adapted to accommodate a flow of drilling fluid. A turbine is disposed within the bore and an actuating assembly is arranged such that a clutch may mechanically connect and disconnect with the turbine.

Description:
FIELD 
     Embodiments of the invention relate to methods and mechanisms to actuate components of downhole tools and, more specifically, downhole tools for oil, gas, geothermal, and horizontal drilling. 
     BACKGROUND OF THE INVENTION 
     Actuating downhole tools disposed in a well-bore is often accomplished by dropping a ball down a bore of a drill string to break shear pins, which upon breaking frees a valve to open or actuate a downhole tool, such as a reamer. Once the shear pins are broken, the downhole tool and, consequently, the drill string must be removed from the well-bore to replace them. Other disadvantages, such as an inability to reset the actuating mechanism of the downhole tool while the downhole tool is still in the well-bore are inherent in this type of design. 
     BRIEF SUMMARY OF THE INVENTION 
     In one aspect of the present invention, a downhole tool string component has at least a first end with an attachment to an adjacent tool string component and a second end spaced apart from the first end for attachment to another adjacent tool string component. The downhole tool string component includes a bore between the first end and the second end and a turbine disposed within the bore. An actuating assembly is arranged in the bore such that when actuated a clutch mechanically connects the actuating assembly to the turbine. When the actuating assembly is deactivated, the actuating assembly and turbine are mechanically disconnected. 
     The actuating assembly may move a linear translation mechanism, which may include a sleeve. The sleeve may have at least one port that is adapted to align with a channel formed in a wall of the bore when the sleeve moves. The actuating assembly may control a reamer, a stabilizer blade, a bladder, an in-line vibrator, an indenting member in a drill bit, or combinations thereof. 
     The actuating assembly may comprise a collar with a guide slot around a cam shaft with a pin or ball extending into the slot. When the collar moves axially, the cam rotates due to the interaction between the pin or ball and the slot. The cam shaft may be adapted to activate a switch plate, which is adapted to engage a plurality of gears. The actuating assembly may comprise at least one solenoid adapted to move a translation member in communication with a switching mechanism. 
     In some embodiments, the actuating assembly comprises a switching mechanism adapted to rotate a gear set in multiple directions. 
     The clutch may be a centrifugal clutch adapted to rotate with the turbine. The clutch may have at least one spring loaded contact adapted to connect the clutch to the shaft. The actuating assembly may be triggered by an increase in a velocity at which the turbine rotates, a decrease in the rotational velocity of the turbine, or a combination thereof. In some embodiments, the clutch may be controlled by a solenoid. The clutch may also be controlled over a wired drill pipe telemetry system, a closed loop system, or combinations thereof. 
     In another aspect of the present invention, a downhole tool string component has at least a first end with an attachment to an adjacent tool string component and a second end spaced apart from the first end for attachment to another adjacent tool string component. The downhole tool string component includes a bore between the first end and the second end and a turbine disposed within the bore. A turbine is disposed within the bore, the turbine being in mechanical communication with a linear actuator that is aligned with a central axis of the tool string component. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective diagram of an embodiment of a drill string suspended in a borehole. 
         FIG. 2   a  is a perspective diagram of a portion of an embodiment of a tool string component that includes a reamer. 
         FIG. 2   b  is a cross-sectional diagram of the embodiment of the tool string component illustrated in  FIG. 2   a.    
         FIG. 3  is a cross-sectional diagram of another portion of the embodiment of the tool string component illustrated in  FIG. 2   a.    
         FIG. 4  is a close-up cross-sectional diagram of the another portion of the embodiment of the downhole tool string component illustrated in  FIG. 3 . 
         FIG. 5  is a close-up perspective diagram of the another portion of the embodiment of the downhole tool string component illustrated in  FIG. 4 . 
         FIG. 6  is a perspective diagram of an embodiment of a switch plate for use in embodiments of the tool string component in a first position. 
         FIG. 7  is a perspective diagram of the embodiment of the switch plate illustrated in  FIG. 6  in a second position. 
         FIG. 8   a  is a close-up cross-sectional diagram of the portion of the embodiment of the downhole tool string component illustrated in  FIG. 2   b  in which a sleeve is in a first position. 
         FIG. 8   b  is a close-up cross-sectional diagram of the portion of the embodiment of the downhole tool string component illustrated in  FIG. 2   b  in which a sleeve is in a second position. 
         FIG. 9  is a cross-sectional diagram of an embodiment of a downhole tool string component that includes a packer. 
         FIG. 10   a  is a cross-section of an embodiment of a downhole drill string component that includes a solenoid-activated clutch. 
         FIG. 10   b  is another cross-section view of the embodiment of a downhole drill string component that includes the solenoid-activated clutch illustrated in  FIG. 10   b.    
         FIG. 11   a  is a cross-section of an embodiment of a centrifugal clutch. 
         FIG. 11   b  is a perspective cut-away of the embodiment of the centrifugal clutch illustrated in  FIG. 11   a.    
         FIG. 12   a  is a cross-section diagram of an embodiment of a downhole drill string component that includes an actuation assembly. 
         FIG. 12   b  is a cross-section diagram of the embodiment of the downhole drill string component that includes the actuation assembly illustrated in  FIG. 12   a.    
         FIG. 13   a  is a cross-sectional diagram of an embodiment of a drill bit. 
         FIG. 13   b  is a cross-sectional diagram of another embodiment of a drill bit. 
         FIG. 14  is a cross-sectional diagram of an embodiment of a reamer. 
         FIG. 15  is a cross-sectional diagram of an embodiment of a stabilizer in a drill string component. 
         FIG. 16  is a perspective diagram of an embodiment of a vibrator. 
         FIG. 17  is a perspective diagram of an embodiment of a turbine for use in a downhole tool string component. 
         FIG. 18   a  is a perspective diagram of an embodiment of a plurality of blades of a turbine. 
         FIG. 18   b  is a perspective diagram of another embodiment of a plurality of blades of a turbine. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  is a perspective diagram of an embodiment of a drill string  100  suspended by a derrick  108  in a well-bore or bore hole  102 . A drilling assembly  103  is located at the bottom of the bore hole  102  and comprises a drill bit  104 . As the drill bit  104  rotates downhole the drill string  100  advances farther into the earth. The drill string  100  may penetrate soft or hard subterranean formations  105 . The drilling assembly  103  and/or downhole components may comprise data acquisition devices adapted to gather data. The data may be sent to the surface via a transmission system to a data swivel  106 . The data swivel  106  may send the data to the surface equipment  110 . Further, the surface equipment  110  may send data and/or power to downhole tools, the drill bit  104 , and/or the drilling assembly  103 . 
       FIG. 2   a  is a perspective diagram of a portion of an embodiment of a downhole drill or tool string component  201  with a reamer  200 . The reamer  200  may be adapted to extend into and retract away from a borehole wall. While against the borehole wall, the reamer  200  may be adapted to enlarge the diameter of the borehole larger than accomplished by the drill bit  104  at the front of the drilling assembly  103 , as illustrated in  FIG. 1 . 
       FIG. 2   b  is a cross-sectional diagram of the embodiment of the reamer  200  illustrated in  FIG. 2   a . A sleeve  202  located within a bore  204  of the tool sting component  201  may comprise ports  203 . The ports  203  may be adapted to divert drilling mud that flows through the bore  204  when the ports  203  are aligned with openings  250  formed in a wall  202   a  of the bore  204 . The diverted drilling mud may engage a piston  205  located in a chamber  251  otherwise isolated from the bore  204  when the ports  203  are not aligned with the openings  250 ; after the drilling mud passes through the chamber  251  the drilling mud is re-diverted back into the bore  204  of the tool string component  201 . As the drilling mud urges the piston  205  to extend, it may push the reamer  200  outward. A ramp formed in the reamer  200  may cause the reamer  200  to extend radially the piston  205  applies an axial force to the reamer  200 . The piston  205  and reamer  200  may stay extended by a dynamic force from the flowing drilling mud. The reamer  200  may be in mechanical communication with a spring  206  or other urging mechanism adapted to push the reamer  200  back into a retracted position in the absence of axial force exerted by the piston  205  while drilling mud is diverted into the chamber  251 . A reamer that may be compatible with the present invention, with some modifications, is disclosed in U.S. Pat. No. 6,732,817 assigned to Smith International, Inc., which is herein incorporated by reference for all that it contains. 
     When the sleeve  202  is moved along direction A such that the ports  203  and openings  250  misalign, the dynamic force provided by the flowing drilling mud is cut off and the reamer  200  retracts. In other embodiments, a pause in drilling mud flow may also cause the reamer  200  to retract. The sleeve  202  may be moved to realign and misalign the ports  203  with the openings  250  on command to control the position of the reamer  200 . In some embodiments, the ports  203  of the sleeve  202  is adapted to partially align with the openings  250 , allowing a flow less than a flow through fully aligned ports  203  to engage the piston  205 , thereby extending the reamer  200  less than its maximum radial extension. Further discussion and explanation of the mechanical structure and the process is made below in a discussion of  FIGS. 8   a  and  8   b.    
       FIG. 3  is a cross-sectional diagram of another portion of the embodiment of the downhole drill string component  201 . The drill string component  201  may comprise an actuating assembly  333  adapted to move the sleeve  202  axially along direction A. In some embodiments, the actuating assembly  333  is a linear actuator. The drill string component  201  may also comprise a turbine  400  in mechanical communication with the actuation assembly  333  wherein the turbine  400  may be involved in triggering and/or powering the actuation assembly  333 . The actuation assembly  333  may engage or disengage a plurality of gears  304 , such as a planetary gear system, adapted to move a linear screw member  1004  connected to the sleeve  202 . 
       FIGS. 4 and 5  disclose a turbine  400  located in the bore  204  of the drill string component  201 . As drilling mud is passed along a fluid path  402  in the drill string component  201 , the drilling mud flowing over one or more blades  400   a , illustrated in  FIG. 5 , of the turbine  400 , thereby rotating the turbine  400 . 
     The turbine  400  is mechanically coupled to a shaft  412   a  at a proximal end  412   b  of the shaft  412   a . The shaft  412   a  is mechanically coupled to a centrifugal clutch  502  at a distal end  412   c  of the shaft  412   a . When drilling mud causes the turbine  400  to rotate, thereby rotating the shaft  412   a , the centrifugal clutch  502  also rotates. Once the centrifugal clutch  502  rotates sufficiently fast, the centrifugal clutch  502  engages a mount  501 , causing the mount  501  to rotate with the turbine  400 . (The operation of the centrifugal clutch is discussed in further detail below and in reference to  FIGS. 11   a  and  11   b .) As the mount  501  rotates, a plurality of weights  555  attached to a distal end  300   b  of a pivotally attached bracket  300   a  may be forced outward away from a central axis  210  of the drill string component  201  while a proximal end  300   c  of the bracket  300   a  moves to push in an axial direction A′ on a collar  503  coupled to a proximal end  401   b  of a shaft  401   a  located below the mount  501 . A driving gear  410  ( FIG. 5 ) disposed on a distal end  401   c  of the shaft  401   a . Thus, the turbine  400  is mechanically coupled through the shaft  412   a , through a clutch  502 , to the shaft  401   a , and consequently the driving gear  410 . 
     The collar  503  may comprise a guide pin  557  that interacts with a guide slot  558  formed in a cam housing. When the collar  503  moves in an axial direction A′ it may rotate the cam  556 . The rotation of the cam  556  may move a switch plate  504  adapted to selectively place the driving gear  410  in contact with a plurality of gears  304 . When activated the plurality of gears  410  may transfer torque from the shaft  401   a  to a linear screw member  1004  ( FIG. 4 ) attached to the sleeve  202 , as illustrated in  FIG. 3 . 
     The guide slot  558  may comprise a section that causes the collar  503  to move in a first direction and another section that causes the collar  503  to move in a second direction away from the first direction. The direction that the collar  503  travels dictates how the driving gear  410  engages the plurality of gears  304 . In a preferred embodiment, the plurality of gears  304  is a planetary gear system that may control the direction that the gears within the planetary gear system rotate. A clockwise or counterclockwise rotation of the gears determines the forward or backward axial movement A of the linear screw member  1004 , as illustrated in  FIG. 3 . 
       FIG. 6  discloses the switch plate  504  that moves the cam  556  in direction  560  as the collar  503  is advanced axially. The switch plate  504  may be positioned such that the driving gear  410  becomes engaged with a first set of gears  666  mounted to the switch plate  504 , thereby engaging the plurality of gears  304 . The engagement of the plurality of gears  304  may rotate a circular rack  567  in a direction  561  that drives a secondary gear set  678  adapted to turn the linear screw member  1004 , as illustrated in  FIG. 3 . 
     As discussed above and in reference to  FIGS. 4 and 5 , a decrease or slowing of the flow rate of the drilling mud and, consequently, the turbine  400  may cause the centrifugal clutch  502  to decouple the shaft  412   a  from the shaft  401   a . When this occurs, the collar  503 , which may be in communication with a spring (not shown) adapted to urge the collar  503  back to its original axial position, moves axially towards the centrifugal clutch  502 , thereby disengaging the driving gear  410  from the plurality of gears  304 . With the driving gear  410  disengaged from the plurality of gears  304 , the plurality of gears no longer drive the linear screw member and the secondary gear set  678  and, consequently, the linear screw member  1004  remains in its last position before the plurality of gears were disengaged. 
     Referring now to  FIG. 7 , should the flow of the drilling mud subsequently increase and, in turn, causing the rotational velocity of the turbine  400  and the shaft  412   a  coupled thereto to increase, the centrifugal clutch  502  will recouple the shaft  412   a  with the shaft  401   a . This causes the collar  503  to re-interact with the pin  557  in its guide slot  558 . The guide slot  558  is formed such that it will cause the cam  556  to push the driving gear  410  in a direction  562  into a position that causes the driving gear  410  to engage with a second set of gears  667  mounted to the switch plate  504 , thereby engaging the plurality of gears  304 . The engagement of the plurality of gears  304  may rotate a circular rack  567  in a direction  563  that drives a secondary gear set  678  to retract the linear screw member  1004 , as illustrated in  FIG. 3 . Thus, the sleeve  202  (shown in  FIG. 2   b ) attached to the linear screw member  1004  may be moved to extend or retract the reamer  200 . 
       FIG. 8   a , and in reference to  FIG. 2   b  and the related text, discloses an arrow  601  indicating the drilling mud flow through the bore  204  of the drill string component  201  when the ports  203  of the sleeve  202  are misaligned with the openings  250 , thereby preventing the flow of the drilling mud through the openings  250 . 
       FIG. 8   b  discloses the ports  203  of the sleeve  202  aligned with the openings  250 . In this instance, drilling mud is partially diverted along a path  602  through the openings  250  and into a channel  608  in which the piston  205  is disposed. The drilling mud engages the piston  205  as discussed above in reference to  FIG. 2   b , thereby causing the piston  205  to move the reamer  200  outward in a direction  603  due to an inclined ramp formed in the blade (discussed in relation to  FIG. 2   b ). 
       FIG. 9  discloses a packer  800  that may be activated in a similar manner as the reamer described above. 
       FIGS. 10   a  and  10   b  are cross-sectional diagrams disclosing an embodiment of a downhole tool component  201   a  that includes a solenoid activated clutch. A first solenoid  1002  and a second solenoids  1003  that acts in a direction opposite of the first solenoid  1002  are in mechanical communication with a translation member  1050  mechanically coupled to a shaft  1401 . The shaft  1401  is coupled to and rotated by a turbine, such as turbine  400  in  FIG. 5  that is discussed above. The shaft  1401  is mechanically coupled to and, consequently, rotates a key gear  1099 . As reference to the drawings makes clear, the key gear  1099  is mechanically coupled through the shaft  1401  to the translation member  1050 . When the first solenoid  1002  is activated, it moves in a first axial direction A″, thereby moving the shaft  1401  and the key gear  1099  in the same direction as the first solenoid  1002 . When the second solenoid  1003  is activated ( FIG. 10   b ), it moves in a second axial direction A″ opposite the first axial direction, thereby moving the shaft  1401  and the key gear  1099  in the same direction as the second solenoid  1003 . Depending on the direction, the key gear  1099  will engage either a forward gear  1098  or a reverse gear  1097 , which will drive a plurality of gears  304   a , such as the plurality of gears  304  discussed above in reference to  FIGS. 4 and 5 , to either extend or retract a linear screw member  1004   a , as above. The translation member  1050  may comprise a length adapted to abut a barrier to control its travel. The translation member  1050  may be biased, spring-loaded, or comprise an urging mechanism adapted to return the translation member  1050 , and, therefore, the key gear  1099 , to an unengaged position when a solenoid, such as first solenoid  1002  or second solenoid  1003 , is not energized. 
     The first solenoid  1002  and the second solenoid  1003  may be energized through either a local or remote power source. A telemetry system, such as provided by wired drill pipe or mud pulse, may provide an input for when to activate a solenoid. In some embodiments, a closed loop system may provide the input from a sensed downhole parameter and control the actuation. 
       FIGS. 11   a  and  11   b  disclose an embodiment of a centrifugal clutch  1502 , such as the centrifugal clutch  502  discussed above in association with  FIGS. 4 and 5 . The centrifugal clutch  1502  comprises grippers  1100  attached to springs  1101 . In this embodiment, when the centrifugal clutch  1502  rotates sufficiently fast a centrifugal force may overcome the spring force and move the grippers  1100  away from a shaft  1412 . At lower rotational velocities the grippers  1100  bear down on the shaft  2401  rotationally locking them together. To engage the centrifugal clutch  1502  the flow of the drilling mud may be reduced; and to disengage the centrifugal clutch  1502  the flow may be increased. 
       FIGS. 12   a  and  12   b  disclose an embodiment of portion of a downhole drill string component  201   b  that includes an actuation assembly  1333  comprising a turbine  1400  connected to a shaft  1412 . When a centrifugal clutch  1502   a  is engaged as described above in reference to  FIGS. 11   a  and  11   b , the collar  1503  may be pushed forward in a similar manner as described above in reference to  FIGS. 4 and 5 . In this embodiment, the collar  1503  may comprise a ball track  1111  adapted to receive a ball  1112  in communication with a cam  1556 . As the collar  1503  is pushed down, the cam  1556  rotates, which moves a translation member  1050   a . Movement of the translation member causes a key gear  1099   a  coupled to a shaft  1401   a  to engage with either a forward gear  1098   a  or a reverse gear  1097   a  as described above in reference to  FIGS. 10   a  and  10   b , which in turn either advances or retracts a linear screw member  1004   b.    
       FIG. 13   a  is a cross-sectional diagram of an embodiment of a drill bit  104   a . The drill bit  104   a  may comprise an actuating assembly  1500   a  patterned after those described above. The assembly  1500  may be adapted to axially move an indenting member  1501  towards a cutting surface  2000  of the drill bit  104   a . The indenting member  1501  may be a steerable element, hammer element, penetration limiter, weight-on-bit controller, sensor, probe, or combinations thereof. 
     In the embodiment of a drill bit  104   b  illustrated in  FIG. 13   b , an actuating assembly  1500   b  may be use to control a flow of drilling mud through a nozzle  1506  disposed in a face  2002  of the drill bit  104   b.    
       FIG. 14  is a cross-sectional diagram of an embodiment a downhole drill string component  201   c  that includes a winged reamer  200   a , which may be pivotally extended away from downhole drill string component  201   c  by using a linear screw member  1004   c.    
       FIG. 15  discloses an embodiment of a downhole drill string component  201   d  that includes an actuation mechanism adapted to extend a stabilizer blade  1234 . As ports  203   a  in a sleeve  202   a  align with a plurality of openings  250   a , the flow of a drilling mud may be partially diverted to engage a piston  205   a  adapted to push the stabilizer  1234  in a direction  603   a  towards a formation. 
       FIG. 16  discloses an embodiment of a downhole drill string component  201   e  that includes an in-line vibrator  1750  disposed within a bore  204   e  of the drill string component  201   e . As a shaft  1401   b  rotates due to activation of a clutch (not illustrated), an off-centered mass  1701  coupled to the shaft  1401   b  is rotated. The in-line vibrator  1701  may reduce the drilling industry&#39;s dependence on drilling jars which violently shake the entire drill string when the drill string gets stuck in a well-bore. The in-line vibrator  1701  may successfully free the downhole drill string component  201   e  and the drill string while using less energy than traditional jars. This, in turn, may preserve the life of the drill string components and its associated drilling instrumentation. In some embodiments, the use of the in-line vibrator  1701  may prevent the drill string from getting stuck in the well-bore in the first place. The distal end  1751  of the shaft  1401   b  may be supported by a spider  1752 . 
       FIG. 17  discloses an embodiment of a downhole drill string component  201   f  that includes a turbine  400   b  with adjustable blades  1760 . A solenoid may be adapted to rotate a cam associated with the blades  1760 . By adjusting the blade  1760 , the revolutions per minute of the turbine  400   b  may be changed, thereby activating or deactivating a centrifugal clutch, such as the centrifugal clutch  502  discussed above in reference to  FIGS. 4 ,  5 ,  11   a , and  11   b.    
       FIGS. 18   a  and  18   b  disclose an embodiment of a plurality of blades  2004   a  ( FIG. 18   a ),  2004   b  ( FIG. 18   b ) of a turbine. The turbine blades  2004   a  and  2004   b  may be configured to produce higher torque at a lower RPM. 
     Whereas the present invention has been described in particular relation to the drawings attached hereto, it should be understood that other and further modifications apart from those shown or suggested herein, may be made within the scope and spirit of the present invention.