Universal coupling system for a drill string

Abstract

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

What is claimed is: 
     
         1 . A universal coupling system for a drill string consisting essentially of:
 a wedge rotor adaptor coupled to the drill string, the wedge rotor adaptor having a blank end and a box connection opposite the blank end, the box connection having an opening;   a first double wedge releasably coupled to the wedge rotor adaptor, the first double wedge having a first wedge protrusion on a first end and a second wedge protrusion on a second end opposite the first end, the first wedge protrusion received in the opening of the box connection of the wedge rotor adaptor;   a double wedge box releasably coupled to the first double wedge, the double wedge box having a first box connection opposite a second box connection, each of the first box connection and the second box connection having an opening, the opening of the first box connection receiving the second wedge protrusion of the first double wedge;   a second double wedge releasably coupled to the double wedge box, the second double wedge having a first wedge protrusion on a first end and a second wedge protrusion on a second end opposite the first end, the first wedge protrusion received in the opening of the second box connection; and   a wedge bearing adaptor releasably coupled to the second double wedge at a first end and to the drill string at a second end opposite the first end, the wedge bearing adaptor having a box connection opposite a pin connection and an opening, the opening of the box connection receiving the second wedge protrusion of the second double wedge.   
     
     
         2 . The universal coupling system of  claim 1 , wherein the first wedge protrusion and the second wedge protrusion of each of the first double wedge and the second double wedge are configured to move within the corresponding box connection transversely to a center axis of the drill string, thereby absorbing forces received by the drill string. 
     
     
         3 . The universal coupling system of  claim 1 , wherein the first wedge protrusion and the second wedge protrusion of both the first double wedge and the second double wedge are offset approximately 90 degrees. 
     
     
         4 . The universal coupling system of  claim 1 , further comprising retainer pins, wherein two or more of the first wedge protrusion of the first double wedge, the second wedge protrusion of the first double wedge, the first wedge protrusion of the second double wedge, and the second wedge protrusion of the second double wedge include a slot for receiving one of the retainer pins. 
     
     
         5 . The universal coupling system of  claim 4 , wherein two or more of the box connection of the wedge rotor adaptor, the box connection of the wedge bearing adaptor, and the first box connection and the second box connection of the double wedge box has an aperture aligning with the corresponding slot and configured to receive the corresponding retainer pin. 
     
     
         6 . The universal coupling system of  claim 1 , wherein each of the box connection of the wedge rotor adaptor and the wedge bearing adaptor and the first box connection and the second box connection of the double wedge box includes a substantially flat bottom surface or a rounded bottom surface. 
     
     
         7 . The universal coupling system of  claim 6 , wherein each rounded bottom surface is shaped to mate with a rounded surface disposed at an end of one or more of the first wedge protrusion and the second wedge protrusion of the first double wedge and the second double wedge. 
     
     
         8 . The universal coupling system of  claim 1 , wherein each of the first double wedge and the second double wedge includes a rounded base, the first wedge protrusion and the second wedge protrusion each extending from the rounded base in opposite directions. 
     
     
         9 . The universal coupling system of  claim 8 , wherein each of the box connection of the wedge rotor adaptor and the wedge bearing adaptor and the first box connection and the second box connection of the double wedge box includes a rounded pocket disposed near an opening of each connection, the rounded pocket mateable with one of the rounded base of the first double wedge and the second double wedge. 
     
     
         10 . A universal coupling system for a drill string comprising:
 a tubular member having a first opening and a second opening, a first cavity extending inwardly into the tubular member from the first opening, and a second cavity extending inwardly into the tubular member from the second opening;   a first adaptor having an opening at a first end and a protrusion at a second end opposite the first end;   a first rounded base having a first wedge protrusion extending from the first rounded base in a horizontal plane and a second wedge protrusion extending from the first rounded base in an opposite direction of the first wedge protrusion in a vertical plane perpendicular to the horizontal plane, each of the first wedge protrusion and the second wedge protrusion having a rounded end surface extending from a substantially flat top surface to a bottom surface parallel to the flat top surface, the first wedge protrusion received in the first opening of the tubular member and the second wedge protrusion received in the opening of the first adaptor;   a second adaptor having an opening at a first end and a protrusion at a second end opposite the first end;   a second rounded base having a first wedge protrusion extending from the second rounded base in a horizontal plane and a second wedge protrusion extending from the second rounded base in an opposite direction of the first wedge protrusion in a vertical plane perpendicular to the horizontal plane, each of the first wedge protrusion and the second wedge protrusion having a rounded end surface extending from a substantially flat top surface to a bottom surface parallel to the flat top surface, the first wedge protrusion received in the second opening of the tubular member and the second wedge protrusion received in the opening of the second adaptor.   
     
     
         11 . The universal coupling system of  claim 10 , wherein each of the first wedge protrusion and the second wedge protrusion include a pair of tapered side surfaces extending between the substantially flat top surface and the bottom surface. 
     
     
         12 . The universal coupling system of  claim 10 , wherein each of the first wedge protrusion and the second wedge protrusion of each of the first rounded base and the second rounded base include a slot disposed near the rounded end surface and extending through the top surface and the bottom surface for receiving a retainer pin. 
     
     
         13 . The universal coupling system of  claim 12 , wherein each of the opening of the first adaptor and the second adaptor and each of the first opening and the second opening of the tubular member has an aperture aligning with the slot and configured to receive the retainer pin, thereby locking the first adaptor and the first opening of the tubular member to the first rounded base and the second adaptor and the second opening of the tubular member to the second rounded base. 
     
     
         14 . The universal coupling system of  claim 10 , wherein each of the opening of the first adaptor and the second adaptor and the first opening and the second opening of the tubular member includes a bottom surface comprising a substantially flat bottom surface or a rounded bottom surface. 
     
     
         15 . The universal coupling system of  claim 14 , wherein the bottom surface comprises the rounded bottom surface and is shaped to mate with the rounded end surface of each of the first wedge protrusion and the second wedge protrusion of the first rounded base and the second rounded base. 
     
     
         16 . A universal coupling system for a down-hole mud motor comprising:
 a double wedge box having a first box connection opposite a second box connection; and a first double wedge and a second double wedge each releasably coupled to the double wedge box and each having a first wedge protrusion offset from a second wedge protrusion, the first wedge protrusion of each of the first double wedge and the second double wedge being received in the first box connection and the second box connection, respectively,   wherein the system is positioned between a bearing pack and a power source.   
     
     
         17 . The universal coupling system of  claim 16 , wherein each of the first double wedge and the second double wedge comprise a rectangular base having a first end and a second end, each of the first end and the second end having a spherical surface, and further wherein each of the first wedge protrusion and the second wedge protrusion extend in opposing directions from the corresponding spherical surface and are offset 90 degrees from each other, each of the first wedge protrusion and the second wedge protrusion having a substantially flat upper surface, a bottom surface parallel to the upper surface, an end surface extending between the upper surface and the bottom surface, and a slot extending through the upper surface and the bottom surface. 
     
     
         18 . The universal coupling system of  claim 17 , wherein the double wedge box comprises:
 a first opening opposite a second opening, each of the first opening and the second opening having a rounded surface for receiving the corresponding spherical base,   a first cavity extending into a center of the double wedge box from the first opening and receiving the first wedge protrusion or the second wedge protrusion,   a second cavity extending into the center of the double wedge box from the second opening and receiving the first wedge protrusion or the second wedge protrusion, each of the first cavity and the second cavity,   a first aperture extending through the double wedge box and the first cavity,   a second aperture extending through the double wedge box and the second cavity, and   one or more retainer pins receivable by the first aperture or the second aperture and the corresponding slot of the first wedge protrusion or the second wedge protrusion, thereby securing the first wedge protrusion or the second wedge protrusion to the double wedge box.   
     
     
         19 . The universal coupling system of  claim 16 , further comprising a first adaptor and a second adaptor each having an opening opposite a pin connection and a cavity extending into the first adaptor and the second adaptor from the corresponding opening, each of the first adaptor and the second adaptor having an aperture extending through the first adaptor and the second adaptor and the corresponding cavity for receiving a retainer pin. 
     
     
         20 . The universal coupling system of  claim 16 , wherein the first wedge protrusion and the second wedge protrusion of each of the first double wedge and the second double wedge are configured to move within the corresponding box connection along a center axis of the slot, the center axis extending along a width of the slot, thereby absorbing forces received by the drill string.