Progressive cavity pump/motor

Abstract

A progressive cavity pump or motor, particularly suitable for hydrocarbon recovery operations, includes a rotor 20 and a stator 10 . Fluid pressure in cavities between the stator and the rotor create torque which rotates the bit. An interior surface of the stator is rigidly secured to the outer housing of the pump stator and defines an interior profile. A substantially uniform thickness elastomeric layer 62 is supported on the outer housing. The pump rotor has an exterior profile which corresponds with the interior profile of the elastomeric layer.

1 - 5 . (canceled)  
   
   
       6 . A method of manufacturing a progressive cavity pump/motor, comprising: 
 providing a stator including an outer housing and an interior surface homogenous with the outer housing and defining an interior profile;    forming an elastomeric layer on the interior profile of the outer housing to form an elastomeric layer interior profile;    providing an internal profile on the stator for rotationally aligning the interior surface of the housing with respect to a mold for molding the elastomeric layer; and    providing a rotor having an exterior profile to correspond with the interior profile of the elastomeric layer and rotatable within the stator with a plurality of axially moving chambers between the exterior profile on the rotor and the interior profile on the elastomeric layer.    
   
   
       7 . A method as defined in  claim 6 , wherein the stator includes an interior profile taper along its axial length.  
   
   
       8 . A method as defined in  claim 7 , wherein the elastomeric layer has an increasing thickness extending axially through the stator, such that a radial thickness of an first end of the elastomeric layer is less than a radial thickness of a second end of the elastomeric layer.  
   
   
       9 . A method as defined in  claim 6 , wherein the interior surface has a varying radial thickness with respect to a generally cylindrical outer surface of the outer housing, such that the radial thickness of an first end of the elastomeric layer is less than a radial thickness of a second end of the elastomeric layer.  
   
   
       10 . A method as defined in  claim 6 , further comprising: 
 providing a reinforcement layer within the elastomeric layer.    
   
   
       11 . (canceled)  
   
   
       12 . A method as defined in  claim 6 , further comprising: 
 positioning a lead measurement tool on the interior profile surface to measure the thickness between the outside diameter of the outer housing and the interior profile surface.    
   
   
       13 . A method as defined in  claim 12 , wherein the lead measurement tool is rotated relative to a centerline of the outer housing; and 
 displaying an indication of varying thickness in response to the lead measurement tool.    
   
   
       14 . A method as defined in  claim 6 , further comprising: 
 monitoring angular position of the interior profile of the housing as a function of internal dimensions of the profile;    determining angular positions of the profile at each end of the outer housing; and    determining a lead of the interior profile in response to the determined angular position or angular positions.    
   
   
       15 - 22 . (canceled)  
   
   
       23 . A method of manufacturing a progressive cavity pump/motor, comprising: 
 providing a stator including an outer housing;    providing an insert member with the interior surface defining an interior profile, and an exterior surface defining an exterior profile to secure the insert member within the outer housing;    supporting a substantially uniform thickness elastomeric layer on the insert member to form an elastomeric layer interior profile;    providing an internal profile on the stator for rotationally aligning the interior surface of the housing with respect to a mold for molding the elastomeric layer; and    providing a rotor having an exterior profile to correspond with the interior profile of the elastomeric layer and rotatable within the stator with a plurality of axially moving chambers between the exterior profile on the rotor and the interior profile on the elastomeric layer.    
   
   
       24 . A method as defined in  claim 23 , further comprising: 
 utilizing an alignment profile on at least one of the insert member and the outer housing for rotationally aligning the interior surface on the insert with respect to the outer housing.    
   
   
       25 . A method as defined in  claim 23 , further comprising: 
 positioning a lead measurement tool on the interior profile surface of the insert member to measure one of a radial thickness between the outside diameter of the outer housing and the interior profile surface on the insert member, and a radial spacing between a centerline of the insert member and the interior profile surface on the insert member.    
   
   
       26 . A method as defined in  claim 25 , wherein the lead measurement tool is rotated relative to a centerline of the outer housing; and 
 displaying an indication of varying measurements in response to the lead measurement tool.    
   
   
       27 . A method as defined in  claim 25 , further comprising: 
 monitoring radial measurements as a function of angular position of the outer housing;    determining radial measurements at angular positions at each end of the outer housing; and    determining the lead of the interior profile in response to the determined radial measurements at angular positions.    
   
   
       28 . A method as defined in  claim 23 , further comprising: 
 providing a reinforcement layer within the elastomeric layer.    
   
   
       29 . A method as defined in  claim 23 , further comprising: 
 forming the elastomeric layer with an increasing thickness extending axially through the stator, such that a radial thickness of one end of the elastomeric layer is less than a radial thickness of an opposing end of the elastomeric layer.    
   
   
       30 . A method as defined in  claim 23 , further comprising: 
 forming the inner profile secured to the outer housing with a varying radial thickness with respect to a generally cylindrical outer surface of the outer housing, such that the radial thickness of one end of the elastomeric layer is less than a radial thickness of an opposing end of the elastomeric layer.    
   
   
       31 . A method as defined in  claim 23 , further comprising: 
 using the progressive cavity pump/motor as a downhole motor for rotating a bit in a well.    
   
   
       32 . A method as defined in  claim 23 , further comprising: 
 determining a spiral pitch of the interior profile with a lead measurement tool.    
   
   
       33 . A method as defined in  claim 32 , wherein the spiral pitch is determined by inserting the lead measurement tool into each end of the interior profile.  
   
   
       34 . A method as defined in  claim 23 , further comprising: 
 measuring radial spacing of the interior profile surface with respect to one of an exterior surface of the outer housing and a central axis of the insert member; and    a maximum radial spacing determines the position of the lead measurement tool.    
   
   
       35 . A method of manufacturing a progressive cavity pump/motor, comprising: 
 providing a stator including an outer housing;    providing an insert member with the interior surface defining an interior profile, and an exterior surface defining an exterior profile to secure the insert motor within the outer housing;    securing the insert member to the outer housing;    supporting a elastomeric layer on the insert member to form an elastomeric layer interior profile;    utilizing an alignment profile on at least one of the insert member and the housing for rotationally aligning the insert member with respect to the elastomeric layer; and    providing a rotor having an exterior profile to correspond with the interior profile of the elastomeric layer and rotatable within the stator with a plurality of axially moving chambers between the exterior profile on the rotor and the interior profile on the elastomeric layer.    
   
   
       36 . A method as defined in  claim 35 , further comprising: 
 positioning the lead measurement tool on the interior profile to measure the thickness between the outside diameter of the outer housing and the interior profile surface.    
   
   
       37 . A method as defined in  claim 36 , wherein the lead measurement tool is rotated relative to a centerline of the outer housing; and 
 displaying an indication of varying thickness in response to the lead measurement tool.    
   
   
       38 . A method as defined in  claim 36 , further comprising: 
 monitoring radial thickness as a function of angular position of the outer housing;    determining radial thickness at angular positions at each end of the outer housing; and    determining the lead of the interior profile in response to the determined angular position or angular positions.    
   
   
       39 . A method as defined in  claim 35 , further comprising: 
 providing a reinforcement layer within the elastomeric layer.    
   
   
       40 . A method as defined in  claim 35 , further comprising: 
 forming the elastomeric layer with an increasing thickness extending axially through the stator, such that a radial thickness of one end of the elastomeric layer is less than a radial thickness of an opposing end of the elastomeric layer.    
   
   
       41 . A method as defined in  claim 35 , further comprising: 
 forming the inner profile secured to the outer housing with a varying radial thickness with respect to a generally cylindrical outer surface of the outer housing, such that the radial thickness of one end of the elastomeric layer is less than a radial thickness of an opposing end of the elastomeric layer.    
   
   
       42 . A method as defined in  claim 35 , further comprising: 
 using the progressive cavity pump/motor as a downhole motor for rotating a bit in a well.    
   
   
       43 . A method as defined in  claim 35 , further comprising: 
 determining a spiral pitch of the interior profile with a lead measurement tool.    
   
   
       44 . A method as defined in  claim 43 , wherein the spiral pitch is determined by inserting the lead measurement tool into each end of the interior profile.  
   
   
       45 . A method as defined in  claim 35 , further comprising: 
 measuring radial thickness of the interior profile; and    forming the elastomeric layer with an increasing thickness extending axially through the stator, such that a radial thickness of one end of the elastomeric layer is less than a radial thickness of an opposing end of the elastomeric layer.    
   
   
       46 - 52 . (canceled)