Motor Power Section with Integrated Sensors

Abstract

The disclosure includes a power section for a bottom hole assembly for use in a wellbore. The power section may include a stator, the stator including a housing, a stator insert, and a payload housing. The payload housing may be positioned on an outer surface of the housing, and the payload housing may include a payload pocket. The power section may include a rotor, the rotor rotatable eccentrically within the stator.

1 . A power section for a bottom hole assembly for use in a wellbore, the power section comprising:
 a stator, the stator including a housing, and a stator insert;   a rotor, the rotor rotatable eccentrically within the stator; and   a sensor package, the sensor package integrated into the power section.   
     
     
         2 . The power section of  claim 1 , wherein the sensor package includes at least part off one or more of a MWD package, LWD package, downhole sensor package, downhole measurement package, or downhole telemetry package. 
     
     
         3 . The power section of  claim 1 , wherein the sensor package comprises at least one of a magnetometer, accelerometer, gyro, temperature sensor, formation resistivity sensor or gamma radiation detector. 
     
     
         4 . A power section for a bottom hole assembly for use in a wellbore, the power section comprising:
 a stator, the stator including a housing, a stator insert, and a payload pocket; and   a rotor, the rotor rotatable eccentrically within the stator.   
     
     
         5 . The power section of  claim 4 , wherein the stator includes a payload housing positioned on an outer surface of the housing, the payload pocket positioned at least partially within the payload housing. 
     
     
         6 . The power section of  claim 5 , wherein the payload housing further comprises a wear pad, the wear pad positioned on an exterior surface of the payload housing. 
     
     
         7 . The power section of  claim 4 , wherein the stator includes a sleeve mechanically coupled within the housing, the payload pocket positioned at least partially within the sleeve. 
     
     
         8 . The power section of  claim 4 , wherein the stator includes a recess formed in an outer surface of the housing, the recess defining at least part of the payload pocket. 
     
     
         9 . The power section of  claim 8 , wherein the stator includes a hatch cover hingedly or removably coupled to the housing, the hatch cover closing the recess when in a closed position. 
     
     
         10 . The power section of  claim 4 , wherein the housing further comprises one or more wireways formed therein, the wireways including wires positioned therein. 
     
     
         11 . The power section of  claim 4 , further comprising at least one sensor positioned within the payload pocket. 
     
     
         12 . The power section of  claim 11 , wherein the at least one sensor is part of one or more of a MWD package, LWD package, downhole sensor package, downhole measurement package, or downhole telemetry package positioned within the payload pocket. 
     
     
         13 . The power section of  claim 11 , wherein the at least one sensor comprises at least one of a magnetometer, accelerometer, gyro, temperature sensor, formation resistivity sensor or gamma radiation detector. 
     
     
         14 . The power section of  claim 4 , further comprising a power source positioned within the payload pocket. 
     
     
         15 . The power section of  claim 14 , wherein the power source is a battery or a generator. 
     
     
         16 . The power section of  claim 11 , further comprising a processor positioned in the payload pocket, the processor electronically coupled to the at least one sensor to gather, receive, store, process, and/or transmit signals from the at least one sensor. 
     
     
         17 . The power section of  claim 16 , further comprising an antenna, acoustic transceiver, or wired connection electronically coupled to the processor. 
     
     
         18 . The power section of  claim 4 , wherein the payload pocket is rotationally aligned with a toolface of the bottom hole assembly. 
     
     
         19 . The power section of  claim 4 , wherein the payload pocket is rotationally aligned opposite a toolface of the bottom hole assembly. 
     
     
         20 . The power section of  claim 4 , further comprising one or more wear pads or knots positioned on an outer surface of the housing of the stator. 
     
     
         21 . A bottom hole assembly for use in a wellbore, the bottom hole assembly comprising:
 a power section, the power section including:
 a stator, the stator having a housing, a stator insert, and a payload housing, the payload housing positioned on an outer surface of the housing, the payload housing including a payload pocket; and 
 a rotor, the rotor rotatable eccentrically within the stator; 
   a flex shaft, the flex shaft mechanically coupled to the rotor and rotatable by the rotor;   an intermediate shaft, the intermediate shaft positioned within the housing and mechanically coupled to the flex shaft, and the intermediate shaft rotatable concentrically with the housing;   a bent sub, the bent sub mechanically coupled to the housing;   a bit shaft, the bit shaft mechanically coupled to the intermediate shaft; and   a drill bit, the drill bit mechanically coupled to the bit shaft.