METHOD OF USING A MAGNETIC MATRIX TO REINFORCE / DIRECT MAGNETIC FLUX IN A BOTTOM WELL FLOW CONTROL VALVE COUPLER AND POWER GENERATOR

Description

1 / 23 “METHOD OF USING A MAGNETIC MATRIX TO REINFORCE / DIRECT MAGNETIC FLUX IN A COUPLER OF "Bottomhole Flow Control Valve and Power Generator" BACKGROUND

[0001] Hydrocarbons, such as oil and gas, are commonly obtained from underground formations that may be located onshore or offshore. The construction of a hydrocarbon production well can include several different stages. Typically, construction begins with drilling a well at a desired well location, well treatment to optimize hydrocarbon production, and the installation of completion equipment to produce the hydrocarbons from the underground formation. During the production of the formation fluid, formation sand can be carried into the flow path. Formation sand tends to be relatively fine and can corrode production components in the flow path.

[0002] When formation sand is expected to be found in the formation fluid, a bottom completion assembly may be installed in the production zone between the formation and the production pipeline, comprising a plurality of sand screen assemblies. Each sand screen assembly typically includes a filter medium, such as a sand screen, to filter fines from the formation fluid. The influx of formation fluids may be balanced in the plurality of influx control devices (“ICDs”) of the sand screen assembly, which are configured to measure the influx of formation fluids along the length of a bottom completion assembly. Traditionally, ICDs are operated using electrical or hydraulic control lines extending from the surface, or through the use of equipment lowered from the surface, or are autonomous in their operation without external control.An addressable ICD can utilize an energy harvesting device to power a drive controller and one or more valves. The energy harvesting device can utilize a turbine in a production flow passage to generate electrical power. The particles in the fluid... Petition 870250091358, dated 07 / 10 / 2025, page 19 / 56 2 / 23 production can corrode or foul the energy harvesting device. A method for separating the energy harvesting device from the formation fluid produced by erosion is desirable. BRIEF DESCRIPTION OF THE FIGURES

[0003] For a fuller understanding of the present disclosure, reference is now made to the following summary description, taken with respect to the accompanying drawings and the detailed description, where similar reference numbers represent similar parts.

[0004] Figure 1 is a diagram that illustrates an exemplary environment for a turbine assembly according to a disclosure embodiment.

[0005] Figure 2 is a perspective view of an adjustable electronic flow control node, according to one embodiment of the disclosure.

[0006] Figure 3 is a top view illustrating an exemplary turbine according to a disclosure embodiment.

[0007] Figure 4 is a schematic diagram illustrating an exemplary turbine assembly according to a disclosure embodiment.

[0008] Figure 5A is a top view illustrating an exemplary turbine with a magnetic coupling according to another embodiment of the disclosure.

[0009] Figure 5B is a top view illustrating an exemplary turbine with a magnetic coupling, according to another embodiment of the disclosure.

[0010] Figure 6 is a perspective view of a valve with a magnetic coupling according to an embodiment of the disclosure.

[0011] Figure 7 is a block diagram illustrating an exemplary computer system according to an embodiment of the disclosure. DETAILED DESCRIPTION

[0012] It should be understood from the outset that, although illustrative implementations of one or more modalities are shown below, the Petition 870250091358, dated 07 / 10 / 2025, page 20 / 56 3 / 23 The disclosed systems and methods can be implemented using any number of techniques, whether currently known or not yet existing. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims, along with their full scope of equivalents.

[0013] As used in this document, the guidance terms “up in the well,” “down in the well,” “above,” and “below” are defined in relation to the location of the earth’s surface relative to the subsurface formation. “Below” and “bottom of the well” are directed to the opposite side of, or away from, the earth’s surface, toward the subsurface formation. “Above” and “above the well” are directed toward the earth’s surface, away from the subsurface formation or a well fluid source. “Fluidically coupled” means that two or more components have communicating internal passages through which fluid, if present, can flow.A first component and a second component can be "fluidically coupled" through a third component located between the first component and the second component if the first component has internal passage(s) that communicate(s) with internal passage(s) of the third component, and if the same internal passage(s) of the third component communicate(s) with internal passage(s) of the second component.

[0014] Hydrocarbons, such as oil and gas, are produced or obtained from underground reservoir formations that may be located on land or at sea. The development of underground operations and the processes involved in removing hydrocarbons from an underground formation typically involve several construction steps, such as drilling a well at a desired location, isolating the well with a barrier material, completing the well with various production equipment, treating the well to optimize hydrocarbon production, and supplying surface production equipment for hydrocarbon recovery from the wellhead.

[0015] During completion operations, a column Petition 870250091358, dated 07 / 10 / 2025, page 21 / 56 4 / 23 of a completion, for example, a packer and at least one sand screen, can be used to isolate a production zone when erosive sand particles are present or anticipated in the fluids produced from the formation, for example, production fluids. The completion operation may include an upper completion chain and a lower completion chain, also called a lower completion assembly. In general, a lower completion assembly comprises at least one sand screen consisting of a base tube with a flow passage and a filter medium, for example, sand screen, arranged around a portion of the base tube. The filter medium may be formed with a filtered flow area formed between the filter medium and the base tube. An adjustable electronic flow control node may be positioned along the base tube and fluidically coupled to the filter medium through the filter flow area.The adjustable electronic flow control node comprises a power harvesting device, a valve body, a flow control valve, and a unit controller with a transceiver. The power harvesting device may be located within the flow passage between the filter medium and the valve body. A flow of production fluids through the flow passage can generate electrical power for the unit controller and the flow control device. The unit controller can actuate the flow control device to position the flow control valve at a desired position within the valve body to measure the flow of production fluids from the flow passage and the valve compartment to an outlet port. The transceiver can receive signals from the well, for example, an electromagnetic signal or a pressure signal, which includes instructions for the position of the flow control valve.

[0016] In some embodiments, electronic flow control nodes can be used to inject a working fluid into the wellbore ring around the respective sand screen assembly. For example, a gravel slurry, an acidifying treatment, a hydraulic fracturing fluid, or a cake breaking fluid can be injected into the wellbore ring.

[0017] In some sports, the inferior completion Petition 870250091358, dated 07 / 10 / 2025, page 22 / 56 5 / 23 may include two or more electronic flow control nodes configured to operate together to achieve a specific objective. For example, the electronic flow control nodes may be opened and / or closed sequentially along the column.

[0018] In some embodiments, the energy harvesting device can be divided into a clean side and a dirty side. The clean side of the energy harvesting device may include a magnetic rotor coupled to a generator shaft. The dirty side of the energy harvesting device may include a turbine with a magnetic hub, also called a magnetic turbine. The magnetic flux between the magnetic rotor and the magnetic turbine can rotationally couple the magnetic rotor and the magnetic turbine. However, the torque capacity of the magnetic flux may limit the speed of the magnetic turbine.

[0019] A Halbach array can offer a solution to the limited torque capacity of magnetic flux. A Halbach array is an orientation of magnetic poles of magnets in a pattern to increase magnetic flux density. A plurality of magnets can be installed in the magnetic rotor and magnetic turbine, arranged in a Halbach array with corresponding pole directions to increase magnetic flux density and thus increase the torque capacity of the magnetic flux.

[0020] Returning to Figure 1, an exemplary environment 100 for a turbine assembly is illustrated. In some embodiments, the well site environment 100 comprises a wellbore 102 extending from a surface location to a permeable subsurface formation 110. The wellbore 102 may be drilled from the surface using any suitable drilling technique. The wellbore 102 may include a substantially vertical portion 104 transitioning into a deviated portion and a substantially horizontal portion 124. In some embodiments, the wellbore 102 may comprise an unconventional, horizontal, deviated, multilateral, or any other type of wellbore. The wellbore 102 may be defined in part by a casing string 106 that may extend from a surface location to a selected location at the bottom of the well. A Petition 870250091358, dated 07 / 10 / 2025, page 23 / 56 6 / 23 casing string 106 may be isolated from the wellbore by means of cement 108. Portions of the wellbore 102 that do not comprise the casing string 106 may be referred to as an open hole. Although the horizontal portion 124 is illustrated as an open hole section, it is understood that the horizontal section may include a casing string 106 and / or cement 108. Although the wellbore environment 100 illustrates a terrestrial underground environment, this disclosure contemplates any wellbore environment, including a subsea environment. In one or more embodiments, any one or more components or elements may be used with underground operations equipment located on offshore platforms, drillships, semi-submersibles, drilling barges, and land-based platforms.

[0021] A production string 112 may be positioned within well 102 and extend from the surface. The production string 112 may be any tubing, pipe or fluid conduit, including, without limitation, drill pipe, production tubing, casing, spiral tubing and any combination thereof. The production string 112 provides a conduit for production fluids extracted from formation 110 to reach the surface. The production string 112 may additionally provide a conduit for fluids to be transported to the bottom of the well and injected into formation 110, as in an injection operation.

[0022] In some modes, the production column 112 can be loosely coupled to a bottom completion 114. For example, the production string 112 can be mechanically and tightly coupled to the bottom completion 114 by a completion assembly 132, for example, an anchor assembly. In some embodiments, the production string 112 can be coupled to the bottom completion by a mechanical coupling 132. The bottom completion 114 can divide the production zone into several production intervals adjacent to the formation 110. The production zone can be the area within the well 102 where various well operations are to be performed using the bottom completion 114, such as production or injection operations.

[0023] As illustrated in Figure 1, completion Petition 870250091358, dated 07 / 10 / 2025, page 24 / 56 7 / 23 lower completion 114 includes an isolation packer 126 and a plurality of sand control screen assemblies 116 axially offset from each other along parts of the lower completion 114. The isolation packer 126 can anchor and seal the lower completion 114 within the production zone. A zonal packer 118 can be placed between each screen assembly 116 to form a seal between the outer surface of the lower completion 114 and the inner surface of the well 102, thus defining the corresponding production intervals. In operation, the screen assemblies 116 can filter particles from the production fluid so that particles and other fines are not produced at the surface and to prevent particles from clogging parts of the lower completion 114.Although screen assemblies 116 are illustrated as being located in a portion of the open borehole of well 102, it is understood that one or more screen assemblies 116 may be arranged in cased portions of well 102. Although a single screen assemblies 116 are illustrated in each production interval, it is understood that 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 or any number of screen assemblies 116 may be located in a given production interval. Although bottom completion 114 is illustrated with multiple production intervals separated by zonal packers 118, it is understood that the production zone may include 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 or any number of production intervals with a corresponding number of zonal packers 118 used therein.Although the bottom completion 114 is illustrated in a horizontal portion 124 of well 102, it is understood that the bottom completion 114 may be located in a vertical portion 104, in a deviated section, in a multilateral section, or in combinations thereof.

[0024] In some modes, the inferior completion 114 can be used to perform various operations in the well. For example, the bottom completion 114 can be used to extract production fluids 120 from formation 110 and transport these fluids 120 to the surface via the production string 112. The production fluids 120 can be water, oil, gas, acids, or any combination thereof.

[0025] In some modes, the inferior completion Petition 870250091358, dated 07 / 10 / 2025, page 25 / 56 8 / 23 114 can be used to inject fluids 122 with various service operations into the surrounding underground formation 110. For example, the bottom completion 114 can be used with hydraulic fracturing operations, steam-assisted gravity drainage (SAGD) operations, well treatment operations, gravel packing operations, acidification operations, or any combination thereof. In this way, the injected fluids 122 can be water, fracturing fluids, steam, gas, aqueous or liquid chemicals, mud, acids, or any combination thereof.

[0026] In some sports, the inferior completion 114 comprises an adjustable electronic flow control node 130, also called eICD 130, located in each production span. The eICD 130 can operate as a flow regulating device, such as throttles and variable valves, to regulate the flow of fluids 120, 122 into and / or out of the lower completion 114. The eICD 130 can receive signals from the surface via a transceiver and actuate the flow regulating devices accordingly, as will be described later.

[0027] Returning to Figure 2, it is possible to describe a perspective view of an adjustable electronic flow control node. In some embodiments, an eICD 200, for example, an adjustable electronic flow control node, may be an embodiment of the eICD 130 shown in Figure 1. The eICD 200 comprises a valve body 202 with a flow path 204 defined thereon, extending between a first fluid port 206 and a second fluid port 208. An energy harvesting device 210 may be disposed along the flow path 204. The flow path 204 may be defined by one or more fluid channels or fluid ducts 222 formed in the valve body 202, and may also include one or more flow chambers 224 fluidically coupling the channels 222 with the first fluid port 206 and the second fluid port 208.In some embodiments, the energy harvesting device 210 is a turbine generator or blade generator that can be driven by fluid flow along the flow path 204. In other embodiments, the energy harvesting device 210 may be... Petition 870250091358, dated 07 / 10 / 2025, page 26 / 56 9 / 23 arranged to be actuated by the flow of fluid external to the body of valve 202, for example, the production flow passing through elCD 200.

[0028] In some embodiments, the production fluid may flow from the second fluid port 208 to the first fluid port 206. In some embodiments, the injection fluid may flow from the first fluid port 206 to the second fluid port 208. The fluid flow from the first fluid port 206 to the second fluid port 208, or vice versa, may be measured by an adjustable valve 212. The adjustable valve 212 may be a needle valve, a globe valve, a poppet valve, a gate valve, a ball valve, or any other suitable type of valve. As illustrated in Figure 2, the adjustable valve 212 may be a needle valve composed of a stem 230, a stem head 226, and a valve seat 228. An actuating mechanism 214 may linearly position the stem head 226 relative to the valve seat 228.The actuation mechanism 214 can move the stem head 226 to a first position with full contact with the valve seat 228 to interrupt the flow of fluid within the flow chamber 224, for example, between the valve seat 228 and the first fluid port 206. The actuation mechanism 214 can move or position the stem head 226 away from or distally to the valve seat 228 in a second position to allow a maximum potential flow rate through the flow chamber 224 and the flow path 204. The actuation mechanism 214 can position the stem head 226 in a third position, also called the measuring position, located between the first and second positions to reduce the flow rate of fluids within the flow path 204 to a desired flow rate.

[0029] In some embodiments, the adjustable valve 212 can establish a desired flow rate along the flow path 204 for different operations. For example, the adjustable valve 212 can be positioned in the second position, i.e., in the fully open position, for fluid injection operations such as acidification, hydraulic fracturing, gravel packing and the like. In some embodiments, the adjustable valve 212 can establish a Petition 870250091358, dated 07 / 10 / 2025, page 27 / 56 10 / 23 desired flow rate for production, for example, the fluid flow from the second fluid port 208 to the first fluid port 206. In some scenarios, the adjustable valve 212 can be placed in the third position to measure the flow rate of production fluids through the flow path 204.

[0030] In some embodiments, the drive mechanism 214 comprises a drive-side magnet 234, a wet-side valve spool 236, and an actuator. The actuator (not shown) may be an electric actuator coupled to the drive-side magnet 234. A drive controller 216 may be communicatively coupled to the actuator to provide power and instructions for establishing a position of the drive-side magnet 234. The drive-side magnet 234 may be magnetically coupled to the wet-side valve spool 236 by a plurality of magnets. One or more sensors 220 may provide feedback to the drive controller 216 about the position of the actuator, the drive-side magnet 234, the rod head 226, or combinations thereof. For example, sensor 220 could be a position sensor coupled to the actuator, to the drive-side magnet 234, to the rod head 226, or combinations thereof.In another scenario, sensor 220 could be a pressure sensor, a temperature sensor, or a flow sensor for measuring the environment inside the flow chamber 224. The unit controller 216 could receive a wireless signal from a transceiver 218, for example, a pressure signal. The unit controller 216 could receive a signal and move the stem head 226 to a first position, a second position, or a third position in response to the signal, with sensor 220 providing position feedback. Although sensor 220 is illustrated as a single sensor located inside the flow chamber 224, it is understood that sensor 220 could be composed of multiple sensors located anywhere inside the valve body 202 and / or outside the valve body 202. Although transceiver 218 is described as a wireless signal receiver, it is understood that transceiver 218 could transmit wireless signals.

[0031] Returning to Figure 3A, it is possible to describe a top view of an exemplary turbine. In some embodiments, a set of Petition 870250091358, dated 07 / 10 / 2025, p. 28 / 56 The turbine 300 of the energy harvesting device 210 can be configured to receive a flow of fluid 312 from a flow path 204 (shown in Figure 2) and convert the kinetic and potential energy of the fluid 312 into rotational motion and torque. The fluid flow 312 can be any type of fluid within the flow path 204, for example, injection fluids and / or production fluids. The turbine assembly 300 can include a turbine body 314 with a plurality of turbine blades 316, a turbine hub 318, and at least one hub magnet 320. The turbine blades 316 can be distributed around the turbine hub 318 and configured to receive the fluid 312. The turbine blades 316 can be blades, plates, fins, or any other suitable element configured to transform the fluid motion into rotational motion. For example, the turbine hub 318 can be stimulated to rotate in response to the impact of fluid 312 on the turbine blades 316.The turbine assembly 300 may be located in a first chamber or in a turbine chamber 326. A shaft 328 may be coupled to the turbine hub 318 at a point on the central shaft and located in a receiving port within the turbine chamber 326. A plurality of hub magnets 320 may be mounted or fixed to the turbine hub 318. Although the turbine hub 318 is illustrated with six hub magnets 320A-H, it is understood that the turbine hub 318 may have 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16 or any number of hub magnets 320. As illustrated in Figure 3, the fluid 312 in the turbine assembly 300 is perpendicular to the central geometric axis 324 of the turbine body 314.Although turbine assembly 300 is illustrated as a cross-flow turbine, it is understood that turbine assembly 300 can be any other type of turbine configured to generate rotational motion from the fluid flow, for example, the fluid flow can be substantially parallel to the rotational geometric axis or central geometric axis 324 of the rotor.

[0032] Now, in Figure 3B, it is possible to describe a schematic diagram illustrating an exemplary energy harvesting device 330. In some embodiments, the energy harvesting device 330 comprises the turbine assembly 300 and a generator 332. The generator 332 consists of a stator Petition 870250091358, dated 07 / 10 / 2025, page 29 / 56 12 / 23 334, a rotor 336, a rotor coupling 338, and a power unit 340 in a compartment 342. The generator 332 may operate in a sealed chamber 344, also called a second chamber, within the compartment 342. The generator 332 may produce electrical energy 346 when the rotor 336 is rotating within the stator 334. A power unit 340 comprises a rectifier circuit 350 and an energy storage device 352 for conditioning and / or storing the electrical energy 346. The stator 334 may comprise a plurality of windings 322 mounted on a core. The rotor 336 may include a plurality of magnets 354 mounted on a rotor shaft 358. A rotor coupling plate 360 ​​may generally have a disc shape with a plurality of plate magnets 362 mounted or fixed to the rotor coupling plate 360. The rotor coupling plate 360 ​​may be rotationally coupled to the rotor 336 by the rotor shaft 358.The rotor coupling plate 360 ​​can be magnetically coupled to the turbine assembly 300. The turbine assembly 300 can be located in the turbine chamber 326, also called the first chamber. For example, a plurality of magnetic flux 366 can extend through a non-magnetic sheath 368 from the plurality of plate magnets 362 to the plurality of hub magnets 320.

[0033] During operation, a fluid flow rate within the flow path 204 can induce rotational motion of the turbine assembly 300. The plurality of magnetic flux 366 can rotationally couple the turbine assembly 300 to the rotor coupling plate 360, so that the rotational motion of the turbine assembly 300 can rotate the rotor 336 within the stator 334 to generate electrical energy 346. The power unit 340 can store and provide a stable power supply for consumption by a load, for example, the unit controller 216.

[0034] In one embodiment, the turbine assembly 300 and the drive mechanism 214 can utilize a magnetic field generated by a Halbach Array to generate a plurality of magnetic fluxes 366 with the rotor coupling plate 360. In general, a Halbach Array comprises an arrangement of permanent magnets that increases the magnetic field on one side of the array. Petition 870250091358, dated 07 / 10 / 2025, page 30 / 56 13 / 23 and cancels the field to almost zero on the other side. The arrangement may include a spatially rotating magnetization pattern. Halbach arrays can be implemented in a variety of formats, such as arrays (bar or rod magnets), sheets, plates, and cylinders (e.g., in the form of Halbach cylinders). When the Halbach array is used with a cylindrical arrangement, the magnetic field can be increased inside or outside the cylinder, with a corresponding decrease in the magnetic field on the opposite side – outside or inside the cylinder, respectively.

[0035] In general, magnets can be manufactured from a material that is magnetized and creates its own persistent magnetic field. In one embodiment, the magnets of the turbine assembly 300 and the drive mechanism 214 can be permanent magnets formed, at least in part, from one or more ferromagnetic materials. Suitable and useful ferromagnetic materials for the magnets described in this document may include, without limitation, iron, cobalt, rare earth metal alloys, ceramic magnets, alnico-nickel-iron alloys, rare earth magnets (e.g., a neodymium magnet and / or a samarium-cobalt magnet). Various materials useful for the magnets of the turbine assembly 300 and the drive mechanism 214 may include those known as Co-netic AA®, Mumetal®, Hipernon®, Hy-Mu-80®, Permalloy®, wherein each of them comprises about 80% nickel, 15% iron and the remainder copper, molybdenum and / or chromium.

[0036] Returning to Figure 4, an exemplary Halbach Array 400 comprising a plurality of magnets 402 can be arranged in a rotation pattern (in this case, right, down, left, up, where “up” indicates north). The exemplary Halbach Array 400 can be used in the drive mechanism 214 as well as 236 and / or 234. The rotation pattern of the permanent magnets 402 increases the magnetic field 410 on a first side 406 relative to the reduced field 408 on the second side 404. The degree of increase and / or cancellation of the reduced field 408, 410 on each side of the permanent magnets 402 can vary depending on several considerations, such as the relative strength of the magnets and / or the alignment and orientation of the magnets. In one example, the increased magnetic field 410 is greater than the decreased field 408. In some embodiments, the relationship between the Petition 870250091358, dated 07 / 10 / 2025, page 31 / 56 14 / 23 The magnetic field strength of the reduced field 408 at a given distance from the magnets and the magnetic field strength of the increased field 410 at a distance from the magnets on an opposite side of the magnets 402 may be in the range of about 1:1000 to about 1:1.5, about 1:100 to about 1:2 or about 1:90 to about 1:4. The increased field 410 of the Halbach Array may increase the amount of torque transfer to the generator 332 and the amount of linear force transferred to the adjusting valve 230.

[0037] Returning to Figure 5A, it is possible to describe a top view illustrating an exemplary turbine body with a magnetic coupling. In some embodiments, the exemplary turbine body 500 comprises a turbine hub 318, a plurality of blades 316, a shaft 328, and an array of Halbach wedge magnets 504. The wedge magnets 504 can generally be wedge-shaped or pie-shaped magnets with a pole or flux oriented in the indicated direction. For example, magnet 504A can be oriented to the left, magnet 504B can be oriented upwards, magnet 504C can be oriented to the right, magnet 504D can be oriented downwards, magnet 504E can be oriented to the left, magnet 504F can be oriented upwards, magnet 504G can be oriented to the right, and magnet 504H can be oriented downwards. The rotation pattern of permanent magnets 504 can increase the magnetic field on a first side 508.In some embodiments, a rotor coupling plate, for example, plate 360, comprises a Halbach array of wedge magnets configured to establish an increased flux plurality, for example, flux 366, with the turbine body 500. The increased flux of the Halbach array between the turbine body 500 and the rotor coupling plate can increase the torque capacity of the generator 332 and increase the potential power output of the energy harvesting device 330.

[0038] Returning now to Figure 5B, it is possible to describe a top view illustrating an exemplary turbine body with an enhanced magnetic coupling. In some embodiments, the exemplary turbine body 520 comprises a turbine hub 318, a plurality of blades 316, a shaft 328, and a Halbach array of narrow-wedge magnets 524. The narrow-wedge magnets Petition 870250091358, dated 07 / 10 / 2025, page 32 / 56 15 / 23 524 magnets are generally wedge-shaped or pie-shaped magnets with a pole or flux oriented in the indicated direction. For example, magnet 524A can be oriented left, magnet 524B can be oriented upward, magnet 524C can be oriented right, magnet 524D can be oriented downward, magnet 524E can be oriented left, magnet 524F can be oriented upward, magnet 524G can be oriented right, magnet 524H can be oriented downward, magnet 524I can be oriented left, magnet 524J can be oriented upward, magnet 524K can be oriented right, magnet 524L can be oriented downward, magnet 524M can be oriented left, magnet 524N can be oriented upward, magnet 524O can be oriented right, and magnet 524P can be oriented downward. The rotation pattern of permanent magnets 524 can increase the magnetic field on a first side 528.In some embodiments, a rotor coupling plate, for example, plate 360, comprises a Halbach array of wedge magnets configured to establish an increased flux plurality, for example, flux 366, with the turbine body 520. The increased flux of the Halbach array between the turbine body 520 and the rotor coupling plate can increase the torque capacity of the generator 332 and increase the potential power output of the energy harvesting device 330.

[0039] Returning to Figure 6, it is possible to describe a perspective view of a drive mechanism with a Halbach array. In some embodiments, a drive mechanism 600 comprises a drive-side magnet 602, a wet-side valve spool 604, and an actuator 606. The actuator 606 may be an electric actuator coupled to the drive-side magnet 602. A drive controller 216 may be communicatively coupled to the actuator 606 to provide power and instructions for establishing a position of the drive-side magnet 602. The drive-side magnet 602 comprises a Halbach array of a plurality of magnets 610 arranged in a rotary pattern. The exemplary Halbach array may include magnets 610 with the orientation up, left, down, right, up, left, down, right, up, and left. The rotating magnet assembly 610 can establish an increased flux, or strong lateral flux 612, Petition 870250091358, dated 07 / 10 / 2025, page 33 / 56 16 / 23 oriented towards the wet-side spool 604 and a decreased flux, or weak lateral flux 614, oriented away from the wet-side spool 604. The wet-side spool 604 comprises a Halbach array of a plurality of magnets 620 arranged in a pattern of down, right, up, left, down, right, up, left, down and right. The rotating assembly of magnets 620 can establish an increased flux, or strong lateral flux 622, oriented towards the drive-side magnet 602 and a decreased flux, or weak lateral flux 624, oriented away from the drive-side magnet 602. The drive-side magnet 234 can be magnetically coupled to the wet-side valve spool 236 by means of a non-magnetic wall 633 with an increased or strong lateral flux 612, 622.

[0040] The drive-side magnet 602, the actuator 606, and the unit controller 216 may be located in a positioning chamber 630 within the valve body 202. The positioning chamber 630, also called the second chamber, may be sealed and isolated from the well environment. The wet-side spool 604 and the valve 212 may be located within the flow chamber 224, also called the first chamber, of the valve body 202. In one scenario, the production fluid may exit from the valve seat 228 to the flow chamber 224 and exit from the first fluid port 206. The valve 212 may be positioned by the wet-side spool 604, located within the flow chamber 224, in a first position, a second position, or a third position, for example, a fully closed position, a fully open position, or a metered position.

[0041] Returning now to Figure 7, a computer system 700 suitable for implementing one or more embodiments of the drive controller, for example, the drive controller 216, including, without limitation, any aspect of the computing system associated with the operation of the valve of Figures 2 and 6. The computer system 700 includes one or more processors 702 (which may be called the central processing unit or CPU) that are in communication with memory 704, secondary storage 706, input and output devices 710, and network devices. The system of Petition 870250091358, dated 07 / 10 / 2025, page 34 / 56 17 / 23 Computer 700 can continuously monitor the state of input devices and change the state of output devices based on a plurality of programmed instructions. The programming instructions may comprise one or more applications retrieved from memory 704 for execution by processor 702 in non-transient memory within memory 704. The input and output devices may comprise a human-machine interface with a display screen and the ability to receive conventional input from service personnel, such as a push button, touch screen, keyboard, mouse, or any other device or element that service personnel may use to enter a command into the computer system 700. Secondary storage 706 may comprise solid-state memory, a hard disk, or any other type of memory suitable for data storage.Secondary storage 706 may comprise removable memory storage devices, such as solid-state memory, or removable memory media, such as magnetic media and optical media, i.e., CD disks. The computer system 700 may communicate with various networks using network devices 714, which comprise wired networks, e.g., Ethernet or fiber optic communication, and short-range wireless networks, such as Wi-Fi (i.e., IEEE 802.11), Bluetooth, or other low-power wireless signals such as ZigBee, Z-Wave, 6LoWPan, Thread, and WiFi-ah. The computer system 700 may include a transceiver 218 for wireless communication.

[0042] In some forms, the computer system The 700 may comprise a DAQ 716 board for communication with one or more sensors. The DAQ 716 board may be a standalone system with a microprocessor, memory, and one or more applications running in memory. The DAQ 716 board may be a card or a device within the 700 computer system. In some embodiments, the DAQ 716 board may be combined with the 710 input / output device. The DAQ 716 board may receive one or more analog inputs, one or more frequency inputs, and one or more Modbus inputs. For example, the analog input may include a position sensor, for example, a linear sensor. For example, the frequency input may Petition 870250091358, dated 07 / 10 / 2025, page 35 / 56 18 / 23 include a flow meter, that is, a fluid system flow rate sensor. For example, the Modbus input may include a pressure transducer. The DAQ 716 card can convert signals received via analog input, frequency input, and Modbus input into the corresponding sensor data. For example, the DAQ 716 card can convert a frequency input from the flow rate sensor into flow rate data measured in gallons per minute (GPM). ADDITIONAL DISCLOSURE

[0043] The following are specific, non-limiting arrangements in accordance with and in accordance with the present disclosure:

[0044] A first embodiment, which is a magnetic coupling mechanism in a downhole flow control tool, comprising a first chamber configured to receive i) production fluids or ii) injection fluids; a first component with a plurality of magnets located within the first chamber, and wherein the plurality of magnets is configured in a Halbach Array; a second chamber configured to exclude a well environment; a second component with a plurality of magnets located within the second chamber and wherein the plurality of magnets is configured in a Halbach Array; wherein the first chamber and the second chamber share a non-magnetic separation; and wherein the first component is magnetically coupled to the second component by a plurality of strong magnetic flux.

[0045] A second embodiment, which is the magnetic coupling mechanism of the first embodiment, in which the plurality of magnets in the first component is configured to produce a weak magnetic flux directed away from the non-magnetic separation and a strong magnetic flux directed towards the non-magnetic separation.

[0046] A third embodiment, which is the magnetic coupling mechanism of either of the first and second embodiments, in which the plurality of magnets in the second component is configured to produce a weak magnetic flux directed away from the non-magnetic separation and a flux Petition 870250091358, dated 07 / 10 / 2025, page 36 / 56 19 / 23 strong magnetic directed for non-magnetic separation.

[0047] A fourth embodiment, which is the magnetic coupling mechanism of any of the first to third embodiments, in which the first component is configured to move axially; and in which the second component is inclined to move axially by the plurality of strong magnetic flux.

[0048] A fifth embodiment, which is the magnetic coupling mechanism of the first through the fourth embodiment, in which the first component is configured to translate rotationally; and in which the second component is inclined to translate rotationally by the plurality of strong magnetic flux.

[0049] A sixth embodiment, which is the magnetic coupling mechanism of any of the first through fifth embodiments, in which the first component and the second component are separated by a non-magnetic separation.

[0050] A seventh embodiment, which is the magnetic coupling mechanism of any of the first through sixth embodiments, in which the downhole flow control tool comprises a valve body with a flow path, an energy harvesting device, an adjustable valve and a unit controller.

[0051] An eighth embodiment, which is the magnetic coupling mechanism of any of the first to seventh embodiments, wherein the flow path comprises a first fluid port within a fluid chamber fluidically coupled to a second fluid port by means of at least one fluid duct; wherein the energy harvesting device comprises a generator and a turbine assembly; wherein the turbine assembly is fluidically coupled to the flow path and located between the second fluid port and the fluid chamber; and wherein the turbine assembly is configured to induce rotation within the generator.

[0052] A ninth modality, which is the mechanism of Petition 870250091358, dated 07 / 10 / 2025, page 37 / 56 20 / 23 magnetic coupling of any of the first to eighth modes, wherein the first component and the second component are located within the energy harvesting device.

[0053] A tenth embodiment, which is the magnetic coupling mechanism of any of the first to ninth embodiments, wherein the adjustable valve comprises an actuating mechanism and a stem head; wherein the actuating mechanism is communicatively coupled to the unit controller; wherein the stem head is located within a fluid chamber; and wherein the actuating mechanism is configured to position the stem head in i) a first position, ii) a second position or iii) a third position.

[0054] An eleventh embodiment, which is the magnetic coupling sealing mechanism of any of the first to tenth embodiments, wherein the first component and the second component are located within the adjustable valve.

[0055] A twelfth embodiment, consisting of a method of actuating a downhole mechanism by a magnetic coupling within a downhole tool assembly, comprising positioning a first component in a first chamber, wherein the first component comprises a plurality of magnets, wherein the plurality of magnets is configured to produce a strong magnetic flux on a first side; positioning a second component in a second chamber, wherein the second component comprises a plurality of magnets, wherein the plurality of magnets is configured to produce a strong magnetic flux on a second side; wherein the first chamber and the second chamber are coupled by a non-magnetic separation; wherein the first side of the first component is oriented towards the non-magnetic separation; wherein the second side of the second component is oriented towards the non-magnetic separation;Magnetic coupling of the strong magnetic flux on the first side of the first component to the strong magnetic flux on the second side of the second component; and actuation of the second component with; Petition 870250091358, dated 07 / 10 / 2025, page 38 / 56 21 / 23 the first component.

[0056] A thirteenth embodiment, which is the twelfth embodiment method, wherein the first chamber comprises a flow path for well fluids; and wherein the second chamber excludes a well environment.

[0057] A fourteenth embodiment, which is the method of the thirteenth embodiment, which further comprises the rotation of the first component with a well fluid flow rate; and the generation of electrical energy within the second chamber in response to a rotational motion of the second component.

[0058] A fifteenth embodiment, which is the method of any one of the thirteenth to fourteenth embodiments, in which the first chamber excludes the wellbore environment; and in which the second chamber comprises a flow path for wellbore fluids.

[0059] A sixteenth embodiment, which is the method of any one of the thirteenth to fifteenth embodiments, which further comprises positioning a first component with an actuator in i) a first position, ii) a second position or iii) a third position; and altering a well fluid flow rate within the flow path with a second component in response to the position of the first component.

[0060] A seventeenth modality, which is the method of any of the thirteenth to fifteenth modalities, in which the well fluids are i) production fluids or ii) injection fluids.

[0061] An eighteenth embodiment, which is a downhole flow control tool system, comprising a first component in a first chamber, wherein the first component comprises a plurality of magnets, wherein the plurality of magnets is configured to produce a strong magnetic flux on a first side; a second component in a second chamber, wherein the second component comprises a plurality of magnets, wherein the plurality of magnets is configured to produce a strong flux Petition 870250091358, dated 07 / 10 / 2025, pp. 39 / 56 22 / 23 magnetic on a second side, and wherein the first chamber and the second chamber are coupled by a non-magnetic separation; a magnetic coupling by strong magnetic flux on the first side of the first component and strong magnetic flux on the second side of the second component; and wherein the magnetic coupling is configured to drive the second component with the first component.

[0062] A nineteenth embodiment, which is the eighteenth embodiment's downhole flow control tool system, wherein the actuation of the second component with the first component further comprises: the rotation of the first component within a flow path with a well fluid flow rate; and the generation of electrical energy within the second chamber excluding a well environment in response to a rotational motion of the second component.

[0063] A twentieth embodiment, which is the eighteenth or nineteenth embodiment downhole flow control tool system, wherein the actuation of the second component with the first component further comprises: the positioning of a first component with an actuator in i) a first position, ii) a second position or iii) a third position, wherein the first chamber excludes a well environment; and the alteration of a well fluid flow rate in a flow path with a second component in response to the position of the first component.

[0064] Although embodiments have been shown and described, modifications thereof may be made by one skilled in the art without departing from the spirit and precepts of this disclosure. The embodiments described in this document are merely exemplary and are not intended to be limiting. Many variations and modifications of the embodiments disclosed in this document are possible and are within the scope of this disclosure. When numerical ranges or limitations are expressly stated, such expressed ranges or limitations shall be understood as including iterative ranges or limitations of similar magnitude that fall within the ranges or limitations expressly stated. Petition 870250091358, dated 07 / 10 / 2025, pp. 40 / 56 23 / 23 declared (e.g., from approximately 1 to approximately 10 includes 2, 3, 4, etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, whenever a numerical range with a lower limit, Rl, and an upper limit, Ru, is disclosed, any number within the range is specifically disclosed. In particular, the following numbers are specifically disclosed within the range: R = Rl + k * (Ru - Rl), where k is a variable ranging from 1 percent to 100 percent in increments of 1 percent, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, ... percent, 51 percent, 52 percent, 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Furthermore, any numerical range defined by two R-numbers, as defined above, is also specifically disclosed. The use of the term “optionally” in relation to any element of a claim is intended to mean that the element in question is necessary or, alternatively, is not necessary. Both alternatives are intended to be within the scope of the claim. The use of broader terms such as comprise, include, have, etc., should be understood as providing support for narrower terms such as consist of, consist essentially of, substantially composed of, etc.

[0065] Therefore, the scope of protection is not limited by the description set forth above, but is limited only by the claims that follow, the scope of which includes all equivalents of the subject matter of the claims. Each and every claim is incorporated into the descriptive report as an embodiment of this disclosure. Thus, the claims are a further description and are an addition to the embodiments of this disclosure. The discussion of a reference in this document is not an admission that it is prior art, especially any reference that may have a publication date after the priority date of this application. Disclosures of all patents, applications and patent publications cited herein are incorporated herein by reference to the extent that they provide exemplary, procedural or otherwise supplementary details to those presented herein. Petition 870250091358, dated 07 / 10 / 2025, pp. 41 / 56

Claims

1 / 6 CLAIMS 1. Magnetic coupling mechanism in a downhole flow control tool characterized in that it comprises: a first chamber configured to receive i) production fluids or ii) injection fluids; a first component with a plurality of magnets located within the first chamber, wherein the plurality of magnets is configured in a Halbach Array; a second chamber configured to exclude the well environment; a second component with a plurality of magnets located within the second chamber, wherein the plurality of magnets is configured in a Halbach Array; wherein the first chamber and the second chamber share a non-magnetic separation; and wherein the first component is magnetically coupled to the second component by a plurality of strong magnetic fluxes.

2. Magnetic coupling mechanism, according to claim 1, characterized in that: the plurality of magnets in the first component is configured to produce a weak magnetic flux directed away from the non-magnetic separation and a strong magnetic flux directed towards the non-magnetic separation.

3. Magnetic coupling mechanism, according to claim 1, characterized in that: the plurality of magnets in the second component is configured to produce a weak magnetic flux directed away from the non-magnetic separation and a strong magnetic flux directed towards the non-magnetic separation.

4. Magnetic coupling mechanism, according to claim 1, characterized in that: the first component is configured to move axially; and the second component is inclined to move axially by the plurality of strong magnetic fluxes.

5. Magnetic coupling mechanism, according to claim 1, characterized in that: the first component is configured to translate rotationally; and in that the second component is inclined to rotational translation by the plurality of strong magnetic flux.

6. Magnetic coupling mechanism, according to claim 1, characterized in that: the first component and the second component are separated by non-magnetic separation.

7. Magnetic coupling mechanism, according to claim 1, characterized in that the downhole flow control tool comprises a valve body with a flow path, an energy harvesting device, an adjustable valve and a drive controller.

8. Magnetic coupling mechanism, according to claim 7, characterized in that: the flow path comprises a first fluid port within a fluid chamber fluidically coupled to a second fluid port by means of at least one fluid duct; wherein the energy harvesting device comprises a generator and a turbine assembly; wherein the turbine assembly is fluidically coupled to the flow path and located between the second fluid port and the fluid chamber; and the turbine assembly is configured to induce rotation in the generator.

9. Magnetic coupling mechanism, according to claim 8, characterized in that the first component and the second component are located inside the energy harvesting device.

10. Magnetic coupling mechanism, according to claim 7, characterized in that: the adjustable valve comprises an actuating mechanism and a stem head; wherein the actuating mechanism is communicatively coupled to the unit controller; wherein the stem head is located in a fluid chamber; and the actuating mechanism is configured to position the stem head in i) a first position, ii) a second position or iii) a third position.

11. Magnetic coupling mechanism, according to claim 10, characterized in that the first component and the second component are located inside the adjustable valve.

12. A method for actuating a downhole mechanism by magnetic coupling in a downhole tool assembly, characterized in that it comprises: positioning a first component in a first chamber, wherein the first component comprises a plurality of magnets, wherein the plurality of magnets is configured to produce a strong magnetic flux on a first side; positioning a second component in a second chamber, wherein the second component comprises a plurality of magnets, wherein the plurality of magnets is configured to produce a strong magnetic flux on a second side; wherein the first chamber and the second chamber are coupled by a non-magnetic separation; wherein the first side of the first component is oriented towards the non-magnetic separation; Petition 870250091358, dated 07 / 10 / 2025, p.44 / 56 4 / 6 wherein the second side of the second component is oriented for non-magnetic separation; magnetically coupling the strong magnetic flux on the first side of the first component; and actuating the second component with the strong magnetic flux on the second side of the second component.

13. Method according to claim 12, characterized in that: the first chamber comprises a flow path for well fluids; and wherein the second chamber excludes the well environment.

14. Method according to claim 13, characterized in that it further comprises: rotating the first component at a well fluid flow rate; and generating electrical energy within the second chamber in response to a rotational motion of the second component. 15.A method according to claim 12, characterized in that: the first chamber excludes the well environment; and the second chamber comprises a flow path for well fluids.

16. A method according to claim 13, characterized in that it further comprises: positioning a first component with an actuator in i) a first position, ii) a second position, or iii) a third position; and altering a flow rate of well fluids within the flow path with a second component in response to the position of the first component.

17. A method according to claim 13, characterized in that the well fluids are i) production fluids or ii) injection fluids. 18.A downhole flow control tool system characterized in that it comprises: a first component in a first chamber, wherein the first component comprises a plurality of magnets, wherein the plurality of magnets is configured to produce a strong magnetic flux on a first side; a second component in a second chamber, wherein the second component comprises a plurality of magnets, wherein the plurality of magnets is configured to produce a strong magnetic flux on a second side, and wherein the first chamber and the second chamber are coupled by a non-magnetic separation; a magnetic coupling by the strong magnetic flux on the first side of the first component and the strong magnetic flux on the second side of the second component; and wherein the magnetic coupling is configured to: actuate the second component with the first component. 19.A downhole flow control tool system according to claim 18, characterized in that the actuation of the second component with the first component further comprises: rotating the first component within a flow path with a well fluid flow rate; and generating electrical energy within the second chamber that excludes a well environment in response to a rotational movement of the second component.

20. A downhole flow control tool system according to claim 18, characterized in that the actuation of the second component with the first component further comprises: positioning a first component with an actuator in i) a first position, ii) a second position, or iii) a third position, wherein the first chamber excludes a well environment; and altering a well fluid flow rate in a flow path. Petition 870250091358, dated 07 / 10 / 2025, p.46 / 56 6 / 6 flow with a second component in response to the position of the first component. Petition 870250091358, dated 07 / 10 / 2025, pp. 47 / 56.

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