Self-Powered Active Vibration and Rotational Speed ​​Sensor

Abstract

A self-powered active sensing system (SASS) for a downhole drilling environment is disclosed. The sensor device of the SASS may include a self-powered rotational speed sensor, which includes a ring structure attached around a drill string. The ring rotates in a groove formed in an outer shell. A support on the ring is arranged to contact a movable member extending from the shell into the groove, so that the movable member generates an electrical signal representing the rotational speed. The SASS may include a vibration sensor having an annular spring mounted in the shell. The spherical support on the outer surface of the ring is configured to contact a screen that is mounted to the shell and generates a signal representing that the support / ring is moved due to vibration. Multiple SASS units configured to wirelessly transmit sensor data can be placed along the drill string, thereby providing a distributed self-powered system for measuring downhole parameters.

Description

Technical Field

[0001] The present invention relates to oil and gas drilling monitoring systems, and more particularly to vibration and velocity sensor systems for use in downhole drilling environments. Background Art

[0002] Nearly all onshore and offshore oil and gas wells use logging-, measurement-, and drilling-dynamic sensor tools. In onshore wells, measurement-while-drilling (MWD) and logging-while-drilling (LWD) tools are often used for directional drilling. In offshore wells, only MWD tools are usually used. Both MWD and LWD tools utilize batteries, turbines, or both to power the sensors and electronics. MWD and LWD systems can obtain logging data while drilling, but are expensive, bulky, and lengthy tools.

[0003] Wireline logging is also used in both onshore and offshore drilling operations. Obtaining logging data via wireline is an expensive process because the drilling assembly must first be pulled out of the wellbore and then the wireline assembly must be run into the wellbore to take measurements. This also means that logging data cannot be obtained while drilling. There is also a risk that the wireline assembly, along with all its expensive sensors and instruments, becomes stuck in the hole, significantly increasing drilling costs.

[0004] In wireline operations, power for cable sensors and instruments is provided by wired power lines that extend from the surface power source all the way to the depth of the well. Power for MWD and LWD is provided by rechargeable lithium battery packs, turbines, alternators, or a combination of these. One of the main disadvantages of lithium batteries is their cost. For example, their manufacturing costs are significantly higher than nickel-cadmium batteries, which is even more obvious when they have to be produced on a large scale for various applications. In order to meet the needs of the factory, more fossil fuels may be required to produce the batteries. In addition, lithium batteries age, depending on the number of charge and discharge cycles they undergo. However, the batteries will eventually expire, resulting in large amounts of polluting waste. Therefore, the use of lithium batteries not only has significant costs during their production life cycle, but also has a negative impact on the environment. The mechanical failure rate of batteries is also generally high and is expected to be higher downhole (i.e., below the wellbore) given the harsh environment to which they are exposed. Turbine / alternators use the kinetic energy of fluid flow to generate electricity. Therefore, they can only generate electricity when there is fluid flow inside the drill string, and the power generated depends on the speed of the fluid flow. For example, heavy mud and lost circulation material in the drill string can significantly reduce flow rates in the drill string and may even block the passage through the turbine / alternator.

[0005] The data obtained by LWD / MWD is not static; rather, it changes over time due to drilling and other operations performed within the wellbore. For example, the log data measured by the LWD / MWD sensors at a specific depth along the wellbore change over time because they are affected by the drilling fluid properties, such as salinity, density, solids concentration, etc., as well as temperature, pressure, hole size and roughness, tool alignment, logging speed, as well as lithology, pore size, type of fluid in the pores, and geological structure and geometry of the rock formation. Therefore, it is impossible to obtain real-time information on these parameters at these depths unless the LWD / MWD sensors are run again at these depths, which is very expensive and not feasible.

[0006] It is with these and other considerations that the disclosure made herein is proposed. Summary of the invention

[0007] According to one aspect of the present disclosure, a self-powered active sensing system is disclosed. The self-powered active sensing system includes a speed sensor for measuring the rotation speed of a drill string. Specifically, the speed sensor includes a first structure in a ring shape, which is configured to be attached around a portion of the drill string. More specifically, the first structure extends circumferentially around the drill string and rotates around the rotation axis of the drill string. In addition, the first structure includes a bearing extending from an outer surface of the first structure.

[0008] The velocity sensor also includes a housing disposed around the first structure and a portion of the drill string. The housing includes an inner wall defining a hollow central opening of sufficient diameter to allow the drill string to pass therethrough. In addition, the inner wall is shaped to define an annular groove extending circumferentially around the central opening. The ring is at least partially received in the annular groove and is rotatable relative to the housing.

[0009] In addition, the speed sensor includes a movable member, which is accommodated in a recess formed in the inner wall of the housing and extends into the annular groove. The movable member is opposite to the support. The movable member and the support are arranged so that when the first structure rotates relative to the housing, the support is configured to contact the movable member, and the movable member is configured to translate into the recess due to contact with the support. In addition, the movable member is configured to generate an analog electrical signal, which represents the rotation speed of the drill string according to the contact between the support and the movable member (analog speed signal).

[0010] According to another aspect of the present disclosure, a self-powered active sensing system for a downhole drilling environment includes a vibration sensor for measuring vibrations of a drill string. More specifically, the vibration sensor includes a housing shaped to extend circumferentially around the drill string, thereby allowing the drill string to rotate within a central opening of the cavity. In addition, the housing includes an inner wall within the housing shaped to define an annular cavity extending circumferentially through the housing. A screen is also provided on a surface of the inner wall defining the annular cavity.

[0011] In addition, the vibration sensor includes a generally annular ring structure. The ring structure is mounted in the annular cavity and is coaxial with the annular cavity. The ring structure also includes a spherical support extending from the outer surface of the first structure facing the screen, wherein the spherical support is configured to contact the screen. In addition, a plurality of springs support the ring in the annular cavity of the housing. The springs are configured to keep the spherical support in contact with the screen and enable the spherical support to move through the screen in one or more directions based on the vibration forces acting on the housing. In addition, the screen is configured to generate an analog electrical signal (analog vibration signal) based on the movement of the spherical support through the screen in one or more directions. The analog vibration signal represents the position of the spherical support on the screen, thereby representing the vibration of the drill string.

[0012] According to another aspect of the present disclosure, a self-powered active sensing system is disclosed. The system includes a housing configured to accommodate a speed sensor for measuring the rotational speed of a drill string and a vibration sensor for measuring the vibration of the drill string. In particular, the system includes a housing that is circumferentially disposed around a portion of the drill string. The housing includes an inner wall that defines a hollow central opening of sufficient diameter to allow the drill string to extend therethrough. The inner wall of the housing is also shaped to define an annular groove that extends circumferentially around the central opening. The housing also includes an inner wall that is shaped to define an annular cavity within the housing and that extends circumferentially through the housing.

[0013] The system also includes a speed sensor for measuring the rotational speed of the drill string. The speed sensor includes a first structure in the shape of a ring, which is configured to be attached around a portion of the drill string. The first structure extends circumferentially around the drill string and rotates around the rotation axis of the drill string. In addition, the first structure includes a support extending from an outer surface of the first structure. The ring is at least partially housed in an annular groove defined by an inner wall of the housing and is rotatable relative to the housing.

[0014] The velocity sensor further includes a movable member housed in a recess formed in an inner wall of the housing and extending into the annular groove. The movable member is opposite to the support, and when the first structure rotates relative to the housing, the support is configured to contact the movable member, and the movable member is configured to translate into the recess due to the contact. In addition, the movable member is configured to generate an analog electrical signal representing the rotational speed of the drill string according to the contact between the support and the movable member (analog velocity signal).

[0015] The system also includes a vibration sensor for measuring vibrations of the drill string. The vibration sensor includes a screen disposed on a surface of an inner wall defining an annular cavity within the housing. Additionally, the vibration sensor includes a ring structure that is generally annular and is mounted within and coaxial with the annular cavity. More specifically, the ring structure includes a spherical bearing extending from an outer surface of the ring structure facing the screen, wherein the spherical bearing is configured to contact the screen.

[0016] The vibration sensor also includes a plurality of springs supporting the ring within the annular cavity of the housing. In particular, the springs are configured to maintain the spherical bearing in contact with the screen and to enable the spherical bearing to move through the screen in one or more directions in response to vibration forces acting on the housing. Based on the movement of the spherical bearing through the screen in one or more directions, the screen is configured to generate an analog electrical signal (analog vibration signal) representing the position of the spherical bearing on the screen, thereby representing the vibration of the drill string.

[0017] According to another aspect of the present disclosure, a self-powered system for real-time distributed monitoring of a downhole drilling environment is disclosed. The system includes a plurality of the aforementioned self-powered active sensing system (SASS) devices, which include a velocity sensor device and a self-powered active vibration sensor. In addition, the plurality of self-powered active sensing systems are distributed along the length of the drill string.

[0018] These and other aspects, features and advantages may be understood from the accompanying description of certain embodiments of the present invention and the accompanying drawings and the like. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1A is a perspective exploded view of an exemplary rotational speed sensor according to one or more disclosed embodiments;

[0020] Figure 1B is a perspective view of an assembled rotational speed sensor according to one or more disclosed embodiments;

[0021] FIG. 2A includes a device disposed on a drill string according to one or more disclosed embodiments. Figure 1A-1B A cross-sectional side view of an exemplary velocity sensor.

[0022] FIG. 2B includes a perspective side view of the velocity sensor of FIG. 2A disposed on a drill string according to one or more disclosed embodiments;

[0023] 2C includes a perspective top view of the speed sensor of FIGS. 2A-2B according to one or more disclosed embodiments;

[0024] Figure 3 A crossover sub (crossover sub) of a drill string is provided according to one or more disclosed embodiments. Figure 1A - A cross-sectional side view of an exemplary speed sensor of 2C and a close-up side view of an exemplary speed sensor on different adapter types;

[0025] 4A is a side view of an exemplary vibration sensor incorporated into a self-powered active sensing system (SASS) according to one or more disclosed embodiments;

[0026] 4B is an isolated top perspective view of the annular component of the vibration sensor of FIG. 4A according to one or more disclosed embodiments;

[0027] 4C is a close-up perspective view of a portion of the vibration sensor of FIGS. 4A-4B , according to one or more disclosed embodiments;

[0028] 4D is a cross-sectional view of a portion of the vibration sensor shown in FIG. 4C according to one or more disclosed embodiments;

[0029] Figure 5A is a side view of the vibration sensor shown in FIG. 4A including a screen assembly according to one or more disclosed embodiments, and includes close-up isolated front plan and side views of a spherical support of the screen and the vibration sensor;

[0030] Figure 5B is a side view of a cross-section of a vibration sensor according to one or more disclosed embodiments, the vibration sensor including a rotating ring structure for mounting an outer housing of the vibration sensor to a drill string;

[0031] Figure 5C is a side view of a cross-section of a vibration sensor according to one or more disclosed embodiments, the vibration sensor including a rotating ring structure for mounting an outer housing of the vibration sensor to a drill string;

[0032] Fig. 6A An isolated front plan view of an exemplary screen and stylus configuration of a vibration sensor including FIGS. 4A-5 according to one or more disclosed embodiments;

[0033] Figure 6B According to one or more disclosed embodiments, Fig. 6Aa close-up side view of the stylus tip moving as the screen moves, and further illustrating a corresponding electrical signal output by the vibration sensor;

[0034] Figure 6C An isolated front plan view of another exemplary screen and stylus configuration of the vibration sensor of FIGS. 4A-5 including one or more disclosed embodiments;

[0035] Fig.6D According to one or more disclosed embodiments, Fig. 7A a close-up side view of the stylus tip moving a portion of the screen, and further illustrating a corresponding electrical signal output by the vibration sensor;

[0036] Fig. 7A is a conceptual illustration of a vibration sensor screen and trace showing vibration-induced movement of a stylus tip over a period of time in accordance with one or more disclosed embodiments;

[0037] Figure 7B is a conceptual illustration of a vibration sensor screen and trace showing vibration-induced movement of a stylus tip over a period of time in accordance with one or more disclosed embodiments;

[0038] Figure 7C is a conceptual illustration of a vibration sensor screen and trace showing vibration-induced movement of a stylus tip over a period of time in accordance with one or more disclosed embodiments;

[0039] Fig.7D is an exemplary heat / contour map visualization of a vibration sensor screen and tracking vibration-induced movement of a stylus tip over a period of time in accordance with one or more disclosed embodiments;

[0040] Fig. 7E is an exemplary heat / contour map visualization of a vibration sensor screen according to one or more disclosed embodiments and tracking vibration-induced movement of a stylus tip over a period of time;

[0041] Figure 7F is a time series of grid images and thermal / contour plots of corresponding vibration traces generated using vibration sensor data according to one or more disclosed embodiments;

[0042] Figure 7G is a diagram showing a method according to one or more disclosed embodiments Figure 5A Conceptual diagram of the placement of four screens around the circumference of the vibration sensor shown;

[0043] Figure 8 According to one or more disclosed embodiments Figure 1A-3A close-up cross-sectional side view of a set of isolated top and bottom movable members and top and bottom supports in an exemplary configuration of a velocity sensor is shown;

[0044] Fig. 9A According to one or more disclosed embodiments Figure 1A-3 A close-up cross-sectional side view of a set of isolated top and bottom movable members and top and bottom supports in another exemplary configuration of a velocity sensor is shown;

[0045] Fig. 9B provides a close-up isolated view of an exemplary assembly configured to hold a movable member in position as the movable member moves within a channel disposed in a second structure in accordance with one or more disclosed embodiments;

[0046] Fig. 10A According to one or more disclosed embodiments Figure 1A-3 A close-up cross-sectional side view of a set of isolated top and bottom movable members and top and bottom supports in another exemplary configuration of a velocity sensor is shown;

[0047] Fig. 10B Close-up isolated views of two exemplary assemblies configured to hold a movable member in place as the movable member moves within a channel disposed in a second structure are provided in accordance with one or more disclosed embodiments;

[0048] Fig.11A According to one or more disclosed embodiments Figure 1A-3 A close-up cross-sectional side view of a set of isolated top and bottom movable members and top and bottom supports in another exemplary configuration of a velocity sensor is shown;

[0049] Fig. 11B provides a close-up isolated view of an exemplary assembly configured to hold a movable member in position as the movable member moves within a channel disposed in a second structure in accordance with one or more disclosed embodiments;

[0050] Fig.12 According to one or more disclosed embodiments Figure 1A-3 A close-up cross-sectional side view of a set of isolated top and bottom movable members and top and bottom supports in another exemplary configuration of a velocity sensor is shown;

[0051] Fig.13A An assembled side view including an isolated side-mounted movable member and a side-mounted support for a velocity sensor shown in a number of possible configurations in accordance with one or more disclosed embodiments;

[0052] Fig. 13B include Fig.13A a cross-sectional side view of a structure;

[0053] Fig.14A shows a side view of an exemplary SASS including a ring-shaped flexible electronic circuit and an antenna transceiver according to one or more disclosed embodiments;

[0054] Fig. 14B is a conceptual diagram of an exemplary electronic device for use in SASS according to one or more disclosed embodiments;

[0055] Fig. 14C is a conceptual block diagram illustrating an exemplary configuration of electronic components of a SASS according to one or more embodiments;

[0056] Fig.14D is a conceptual block diagram illustrating an exemplary configuration of electronic components of a SASS according to one or more embodiments;

[0057] Fig.14E is a conceptual block diagram illustrating an exemplary configuration of electronic processing components of a SASS according to one or more embodiments;

[0058] Fig.15A an isolated front plan view of another exemplary screen and stylus configuration including a vibration sensor according to one or more disclosed embodiments;

[0059] Fig. 15B According to one or more disclosed embodiments, Fig.15A a close-up side view of the stylus tip moving a portion of the screen, and further illustrating a corresponding electrical signal output by the vibration sensor;

[0060] Fig.16 According to one or more disclosed embodiments, Figures 15A-15B A circuit diagram of a resistor-capacitor-inductor circuit that converts the electrical parameters of the screen into a resonant frequency signal;

[0061] Fig.17A an isolated front plan view of another exemplary screen and stylus configuration including a vibration sensor according to one or more disclosed embodiments;

[0062] Fig. 17B According to one or more disclosed embodiments, Fig.17A a close-up side view of the stylus tip moving a portion of the screen, and further showing a circuit diagram for measuring a signal representative of the vibration;

[0063] Fig.18is a perspective side view of an exemplary sensor system including a plurality of SASSs according to one or more disclosed embodiments;

[0064] Fig.19 is a perspective side view of an exemplary sensor system including a plurality of SASSs according to one or more disclosed embodiments; and

[0065] Fig. 20 is a conceptual diagram of an exemplary control computing device for a SASS system according to one or more disclosed embodiments. DETAILED DESCRIPTION

[0066] As an overview and introduction, the systems and methods disclosed herein relate to a self-powered active sensing system (SASS) for a downhole drilling environment. According to one or more embodiments, a sensor device including a self-powered rotational speed sensor and a self-powered tri-axial vibration sensor is disclosed. In addition, a SASS system including one or more vibration sensors and speed sensor devices disposed along a drill string assembly is disclosed. In addition, according to one or more embodiments, a sensor system is disclosed that includes a network of SASS sensors disposed along a drill string assembly, and a system and method for communicating and transmitting measurement data from within a wellbore to the surface.

[0067] The drilling assembly used to drill hydrocarbon wells consists of a hollow steel drill pipe with a drill bit at the bottom. The drill bit is a cutting tool that rotates and penetrates the rock formations below the ground to reach hydrocarbon reservoirs thousands of feet underground as safely and quickly as possible. Three drill pipes connected together, such as a 90-foot long drill pipe (called a "stand"), are rotated and lowered into the wellbore to penetrate the rock formations. The process is repeated until the target well depth is reached. Survey and logging tools, such as wireline and measurement while drilling, logging while drilling (MWD / LWD) tools, play a vital role in the drilling process because the driller cannot see the trajectory of the well being drilled and the downhole environment. Wireline and MWD / LWD tools acquire accurate data that provides an accurate representation of the downhole conditions of the well so that the driller can make effective and timely decisions.

[0068] In wireline operations, power to the wireline sensors and instruments is provided by a wired power line that extends from a surface power source to the depth of the well. However, because the drilling assembly must first be pulled out of the wellbore before running the wireline tool, downhole logging data is not available while drilling. MWD / LWD tools obtain real-time data while drilling and transmit that data to the surface through a technology called mud pulse telemetry. Power to MWD / LWD tools is typically provided by non-rechargeable, single-use, disposable lithium thionyl chloride battery packs. However, if these batteries are exposed to temperatures exceeding 180°C, the lithium metal in the battery will melt, which can cause a violent, accelerated reaction and explosion with enough force to create a hole in the pressure housing, damaging the tool. Batteries are also expensive and discharge over time. This process is accelerated at high temperatures, requiring maintenance or replacement, and increasing the cost of safe disposal due to the chemicals they contain. Turbines / alternators that generate electricity using the kinetic energy of the fluid flow are used to provide power to the most power-hungry parts of the LWD / MWD tool, data acquisition, and transmission of that data to the surface. However, the power produced is proportional to the flow rate of drilling fluid and heavy drilling fluid, for example, lost circulation material in the drill string can significantly reduce the flow rate in the drill string and may even block the path through the turbine / alternator.

[0069] According to one or more disclosed embodiments, an exemplary SASS for a downhole drilling environment includes a rotational speed sensor, a 3-axis vibration sensor, or both. These sensors are referred to as "active" sensors because they are configured to generate and transmit output signals themselves without obtaining power from an external power source. Each of the rotational speed sensor and the vibration sensor outputs a signal corresponding to the rotation and vibration of the drill string component. Specifically, the signal generated by the rotational speed sensor can be used to determine the rotational speed (e.g., revolutions per minute (RPM)) of the drill string. The signal generated by the vibration sensor can be converted into one or more vibration measurements, including, for example, but not limited to, the amplitude, duration, and frequency of the drill string vibration.

[0070] Thus, a SASS containing both sensors can provide real-time, dynamic vibration analysis and revolutions per minute (RPM) data for use by the drilling control system to optimize drilling parameters and maintain efficient drilling. By measuring the amplitude, duration, and frequency of vibration, SASS can help reduce damage to the drill bit and other tools in the drill string assembly. For example, real-time rotational speed and 3-dimensional vibration data (amplitude and imaging) can be used to analyze common drilling problems such as axial / lateral vibration and stick / slip. In addition, measuring RPM as well as vibration provides a good understanding of the impact of vibration on drill bit life. This information can be used to predict downhole drill bit wear as well as the integrity of downhole tools. More generally, drillers can use the data obtained by these sensors to change drilling parameters to mitigate potential downhole problems and optimize drilling operations.

[0071] As described above, in one or more exemplary embodiments, the vibration and RPM sensors are designed to be active so that they do not require batteries to operate and will always function while the drill string assembly is drilling. Unlike using an external power source, the SASS, and more specifically the vibration and RPM sensors, utilize the rotation of the drill string assembly during the drilling of a hydrocarbon well and collect the energy generated thereby to generate electrical signals representing vibration and velocity, along with power generation to power other downhole sensors and SASS instruments. Therefore, the SASS is able to obtain information about the surrounding geological formations and directional data of the wellbore during the drilling process.

[0072] SASS can offer significant advantages over current downhole power generation methods (e.g., batteries and turbines) in terms of size, cost, mobility, temperature / pressure tolerance, and potential downhole applications. In addition, SASS addresses the limitations / challenges of current drilling automation / digitalization and the Fourth Industrial Revolution (4IR) because, for example, batteries cannot power the Industrial Internet of Things (IoT) on a large scale. Because SASS are self-powered, they can be placed along drill string components for distributed sensing of downhole parameters while drilling. This addresses a critical automation / digitalization gap in drilling because the data obtained by LWD / MWD data may not remain constant and may change over time due to drilling and other operations performed within the wellbore. For example, well logging data measured by LWD / MWD sensors at a specific depth along the wellbore may change over time because they are affected by drilling fluid properties (e.g., salinity, density, solids concentration, etc.) as well as temperature, pressure, size and roughness of the wellbore, tool alignment, logging speed, as well as lithology, pore size, type of fluid in the pores, and geological structure and geometry of the rock formation. Therefore, it is not possible to obtain real-time information on these parameters at these depths unless LWD / MWD sensors are run again at these depths, which is very expensive and infeasible. By deploying a system including multiple SASSs along the drill string, a real-time profile of the wellbore can be obtained during drilling. This real-time data profile enables drilling operations to leverage emerging technologies consistent with 4IR, including, for example, but not limited to, big data analytics and artificial intelligence to transform this data into high-value, actionable insights.

[0073] Self-powered rotation speed sensor

[0074] In one or more embodiments, a self-powered rotational speed sensor is disclosed. Although the exemplary speed sensor described herein comprises a portion of a SASS that is also configured to include a 3-axis vibration sensor, it should be understood that the rotational speed sensor may form a stand-alone sensor unit.

[0075] Figure 1Ais a perspective exploded view of an exemplary rotational speed sensor 100. The speed sensor 100 is exploded to show the first structure 110 shown separated from the second structure 120. Figure 1B is a perspective view of the assembled first and second structures.

[0076] The first structure 110 is configured to be attached to the drill string 105 (not shown) so that it extends circumferentially around a portion of the drill string, such as a ring or collar. Thus, the first structure is generally annular, for example, a cylinder having a hollow central opening whose diameter corresponds to the outer diameter of the drill string. Thus, during drilling, the first structure 110 rotates with the drill string about its central axis.

[0077] The outer shell is also called the second structure 120, and is arranged around the first structure 110. Figure 1A-1B As shown, the second structure 120 can be generally shaped as a cylinder with a hollow central opening, the diameter of which is sufficient to allow the drill string to pass through the center of the second structure. The second structure is also configured to at least partially accommodate the annular first structure. In addition, the inner surface of the second structure, which is the surface defining the central opening, can be shaped to include an annular groove 122. The first structure and the groove have complementary sizes and shapes so that at least the outer portion of the ring is located within the annular groove. Although the outer wall of the second structure is cylindrical, other shapes of housings can also be used as long as the housing has a central opening that allows the drill string to extend through it and rotate freely within the opening.

[0078] In use, the first structure 110 rotates within the annular groove about a central axis shared by the first structure, the drill string and the second structure. The second structure 120 is also disposed around the drill string but is configured to remain stationary while the drill string and the first structure rotate within the central opening of the second structure.

[0079] The first structure 110 has top and bottom ball bearings 115T and 115B (collectively referred to as ball bearings 115) which are respectively disposed on the top and bottom surfaces of the first structure 110 and are spaced circumferentially apart. The bearings can guide the first structure to rotate within the groove of the second structure 120, thereby maintaining the relative position of the ring and the second structure.

[0080] The second structure includes top and bottom movable members 125T and 125B (collectively referred to as movable members 125). Figure 1A-1B As shown, the top and bottom movable members extend from the top and bottom surfaces of the annular groove 122 opposite the top and bottom surfaces of the first structure, respectively. The top and bottom movable members are circumferentially spaced around the annular groove. The first structure may also include a ball bearing 115S extending from the outer side surface.

[0081] In the exemplary embodiments of the velocity sensor shown and described herein, it is assumed that the bearing has negligible friction, thereby allowing the second structure to remain stationary while the first structure and the drill string rotate therein. However, the second structure may be provided with one or more external engagement features that are configured to ensure that the second structure remains stationary when the first structure rotates. For example, in the event that turbulent or irregular flow of a fluid causes the second structure to rotate in a vertical well, modifications to the second structure may be included, such as grooves (flutes) or teeth provided on the outer body of the second structure to eliminate such effects. It should also be understood that although the various bearings used to guide the rotation of the first structure relative to the second structure are referred to herein as ball bearings, other suitable types of bearings may also be used, such as roller bearings, needle bearings, etc.

[0082] The support 115 and the movable member 125 are arranged so that during rotation of the drill string component, the support 115 contacts the movable member 125 and moves the movable member upward or downward in the longitudinal direction. Figure 8 -13 further describes, the movable members are constructed so that their contact with the support and / or their movement from contact with the ball bearing generates a series of electrical pulses representing the rotational speed of the drill string assembly. The outputs of the movable members can be connected so that they collectively output a single pulse per cycle. The outputs of the movable components can also be wired so that the signal includes separate pulses from all movable members. In addition, according to a significant aspect, the electrical pulses generated by the speed sensor can be stored to power other components of the SASS, such as signal processors, instrumentation, communications equipment, powered sensors, and other such powered devices on the SASS. Therefore, the sensor is called "active" and the system is "self-powered".

[0083] The spacing of the supports can be independent of the spacing of the movable members. For example, there can be more supports than movable members or more movable members than supports. The spacing between the movable members does not have to be consistent, but the spacing between the supports is preferably the same due to the stability of the system. Although the number of movable members and supports can vary, the number of supports and movable members can depend on the available space around the SASS. In addition, in some exemplary configurations where the spacing between the movable members is not the same, the pulse sequence generated when the drill string assembly rotates counterclockwise and clockwise may be different, so this sequence can be used to uniquely identify the direction of the drill string rotation.

[0084] The first and second structures 110 and 120 can be made of any low friction, metal / non-metal material or composite material that can operate at high temperatures (e.g., >150°C) and high pressures (e.g., >5000psi), and also preferably have wear resistance that can operate in the expected environment. Figures 2A-2C show a SASS 10 that includes a velocity sensor 100 mounted on the outside of a drill string assembly 105 having a drill bit 107 for drilling a well. Figure 2A includes a cross-sectional side view of the velocity sensor 100. Figure 2B includes a perspective side view of the velocity sensor on the drill string 105. Figure 2C includes a perspective top view of the velocity sensor 100. As shown, the first structure 110 is attached to the drill string 105, while the second structure 120 is not. As can be seen from Figure 2A, the ball bearings including top and bottom bearings 115T and 115B and side ball bearings 115S keep the second and first structures aligned. The ball bearings 115 preferably have negligible friction so that the second structure 120 remains stationary while the first structure 110 rotates with the drill string component. According to one or more embodiments, an exemplary configuration of a SASS including a velocity sensor 100 is arranged in a manner that allows for maximum drilling fluid bypass.

[0085] In addition to or as an alternative to providing a SASS including a velocity sensor 100 system on a drill pipe of a drill string 105, the sensor 100 may be mounted to a drill string component via a transition joint 300, such as Figure 3 shown. Figure 3 A side view of a drill string 105 including a transition sub 300 with an exemplary SASS 10 with a velocity sensor 100 disposed thereon is included. Figure 3 Also included is a close-up view of the sensor 100 disposed on a transition joint 300 of the pin-box, pin-pin, or box-box type well known in the drilling art.

[0086] As an alternative to providing the SASS including the velocity sensor on the outside of the drill string, the first and second structures can be disposed in a hollow space within the drill string 105. In this configuration, the first structure 110 can be connected to the inner wall of the drill string assembly and configured to rotate around the central second structure. The first structure is connected to the drill rod in the drill string assembly. In this configuration, the annular first structure similarly includes top and bottom ball bearings and side ball bearings protruding from the inner side wall of the annular first structure. The second structure similarly includes a cylindrical structure with an annular groove that is complementary in size and shape to the first structure and includes top and bottom movable members extending into the groove. However, the annular groove is disposed on the outer surface of the second structure in this configuration. Therefore, during drilling, the first structure will rotate as the drill string assembly and the support of the ring straddle the annular groove extending around the outside of the central second structure.

[0087] Three-axis vibration sensor

[0088] In one or more embodiments, a three-axis vibration sensor is disclosed. Although the exemplary SASS 40 including the vibration sensor 400 described herein includes components of the SASS 10 including the velocity sensor 100 described above, it should be understood that the vibration sensor 400 may form a stand-alone sensor unit.

[0089] FIG. 4A is a side view of an exemplary SASS 40. The SASS 40 includes Figure 1A - The SASS 10 of the rotational speed sensor 100 of FIG. 2C (omitted for simplicity) is the same, but also includes a vibration sensor 400. FIG. 4B is an isolated top perspective view of the ring 420 component of the vibration sensor 400. While FIG. 4A shows the SASS 40 in an assembled state, FIG. 4C is a close-up perspective view of a portion of the vibration sensor 400 within the dashed rectangle shown in FIG. 4A. FIG. 4D is a cross-sectional view of the vibration sensor 400.

[0090] As shown in FIG. 4B , the 3-axis vibration sensor 400 includes a ring structure 420 (hereinafter referred to as a “vibration ring”). For example, the vibration ring is generally cylindrical with a relatively large hollow center opening. Ball bearings 425 are at least partially mounted within the vibration ring, and the ball bearings 425 are circumferentially spaced and supported by the vibration ring so that they protrude at least partially from the outer side surface of the vibration ring. In the exemplary vibration sensor 400, four evenly spaced bearings 425 are provided. The ball bearings 425 are also referred to as spherical tips or styluses.

[0091] The vibration ring is configured to be enclosed within the cylindrical second structure 120, both of which extend completely around the drill string. In particular, the vibration ring is located in a cylindrical cavity 430 that extends circumferentially through the cross-section of the generally cylindrical second structure 120. The vibration ring is supported by a set of springs 415 at multiple circumferential locations. In the exemplary configuration shown in Figures 4A, 4C, and 4D, a set of three springs 415 are provided at each circumferential location, one spring extending from the top boundary wall of the cavity to the top wall of the vibration ring, one spring extending from the bottom boundary wall of the cylindrical cavity to the bottom wall of the ring, and one spring extending from the inner boundary wall of the cavity to the inner wall of the vibration ring. In this way, the spring-supported vibration ring "floats" within the cylindrical cavity of the second structure so that it can move within the cavity in response to forces acting on the second structure (including movement, vibration, etc.).

[0092] The support 425 is configured to act as a spherical tip or stylus that contacts a screen 440 disposed on an opposing surface of the second structure 120. One or more screens 440 are disposed on an outer boundary wall of the cylindrical cavity facing the outer surface of the vibrating ring 420. Figure 5A 4A , but also shows certain components of the velocity sensor 100 housed within a second structure 120 , which also serves the purpose of mounting the second structure 120 to the drill string in a manner that can transmit vibration forces from the drill string to the vibration sensor 400 .

[0093] Figure 5A Also shown is a screen 440 provided for each of the four spherical supports 425. As shown, a corresponding screen 440 can be disposed opposite each spherical tip and can be sized, shaped, and positioned relative to the supports so that the tip contacts the screen throughout the range of motion of the spherical tip. The spherical tips 425 and screens 440 disposed at circumferential locations around the sensor 400 are referred to as a vibration sensor subunit.

[0094] The screen 440 comprises a grid of sensors covering the area contacted by the spherical tip.The vibrating ring comprises supports positioned relative to the screen such that displacement of the vibrating ring due to vibrations moves the stylus tip over the grid in at least the vertical 402 and lateral 404 directions. Figure 5AAlso included are close-up isolated front plan and side views of the spherical support 425 and screen 440. As shown, the spherical support preferably contacts the screen near its center point when at rest, and can move along the screen in the vertical direction 402 and the lateral direction 404, and preferably maintains contact with the screen surface throughout its range of movement. The screen is arranged so that movement of the stylus tip across the screen generates a series of electrical pulses that are representative of the vibrations of the drill string assembly. The electrical pulses generated from the vibration sensor 400 can also be stored to power the signal processing instrumentation of the SASS. Furthermore, the vibration sensor is "active" and the system is "self-powered."

[0095] 4A shows the vibration sensor 400 disposed within the upper half of the second structure 120 above the velocity sensor 100 (not shown), the vibration sensor 400 may similarly be disposed in the lower half of the second structure 120. As noted, the vibration sensor 400 may also be provided as a stand-alone sensor device.

[0096] Preferably, the second structure is mounted around the drill string in a manner such that when the drill string rotates within the central opening of the second structure, the second structure remains relatively stationary. However, the second structure is coupled to the drill string so that vibration forces of the drill string are transmitted to the second structure, enabling these forces to be measured using a vibration sensor. For example, Figure 5B and 5C Two exemplary configurations of mounting the second structure 120 to the drill string using the rotating ring structure 110 and the support 115 of the velocity sensor 100 are shown. In particular, Figure 5B A cross section of a rotating ring structure 110 mounted to a drill string and disposed within an annular groove of an inner wall of a second structure is shown. As shown, the side, top, and bottom ball bearings are arranged to move within corresponding moving tracks formed in the second structure 120. Specifically, the top, side, and bottom ball bearings 115T, 115S, and 115B are arranged to move within the top, side, and bottom moving tracks 555T, 555S, and 555B, respectively. The moving tracks are essentially grooves formed in the top and bottom surfaces of an annular groove formed in the inner wall of the second structure 120. As the rotating ring 110 rotates within the annular groove, the tracks guide the movement of the ball bearings. Figure 5C A slightly different configuration is shown in which a plurality of lateral moving tracks 555S' are disposed in the side walls of the annular groove and are configured to receive a plurality of lateral rows of ball bearings 115S' protruding from the side walls of the first structure 110. Thus, it can be appreciated that the first and second structures are mechanically coupled via ball bearings extending through the side and top / bottom surfaces of the rotating ring within the annular groove.

[0097] During drilling of the well structure, the inner rotating ring 110 will rotate with the drill string assembly. The ball bearings preferably have negligible friction so that when the rotating ring rotates with the drill string assembly, the outer second structure remains stationary. Any vibration of the drill string assembly is the same for the first structure and will be transmitted to the outer second structure 120 via the ball bearings.

[0098] A number of different screen and spherical tip configurations may be used in vibration sensor 400 in accordance with one or more disclosed embodiments. Figures 6A-7B Two exemplary configurations of the vibration sensing subunit of the vibration sensor 400 are shown. In either configuration, preferably, the spherical tip is designed so that it can move along and contact the screen. The outer layer of the screen that contacts the tip is flexible and sensitive to the movement of the spherical tip, while the rigid inner layer connected to the inner surface of the second structure 120 provides mechanical stability for the screen.

[0099] Fig. 6A An isolated front plan view of an exemplary construction of a vibration sensor subunit in accordance with an embodiment is included. The subunit includes a stylus 425 and a screen 640 having a checkerboard-like grid-like structure with alternating squares (shown as black and white for illustration purposes). Each square of the grid can be connected to a signal analysis circuit in a manner such that signals from individual squares are distinguishable and the square that produces the electrical signal can be uniquely identified (e.g., by its coordinates in the array). The squares can be of any size, however, the size of the individual segments can be defined based on the desired sensitivity of the sensor. Alternatively, the screen can include repeating patterns of other shapes, including repeating rectangles, diamonds, circles, ellipses, and polygons of any size. In Fig. 6A In the exemplary arrangement shown, the black and white squares represent segments made of materials A and B, respectively, and the spherical tip is made of material A.

[0100] During drilling, the drill bit at the bottom of the drill string assembly passes through the downhole rock formation, which causes the drill string assembly to vibrate. During vibration, the vibration ring inside the SASS 40 will move according to the direction of vibration. Because multiple vibration sensor subunits including screen 640 and spherical tip 425 can be positioned circumferentially around the SASS, the sensor 400 can detect vibrations on all three axes x, y and z. External mechanical stimulation, vibration amplitude and frequency can be detected by the position of the spherical tip moving along the grid and the change of the tip position over time. The movement of the spherical tip on the array segment causes contact and separation between material A and material B. Material A and material B have opposite polarities or polarities as far away from each other as possible. For example, but not limited to, materials A and B can be made of materials such as polyamide, polytetrafluoroethylene (PTFE), polyethylene terephthalate (PET), polydimethylacrylamide (PDMA), polydimethylsiloxane (PDMS), polyimide, carbon nanotubes, copper, silver, aluminum, lead, elastomer, Teflon, Kapton, nylon or polyester.

[0101] The generation of electrical impulses through friction is based on the electrical charge of an object after it comes into contact with another material through friction. When two materials, such as material A and B, come into contact, the charge moves from one material to the other. Some materials tend to gain electrons and some tend to lose electrons. If material A has a higher polarity than material B, then electrons are injected from material B into material A. This creates surfaces with opposite charges. When the two materials are separated, due to the imbalance of charge between the two materials, a current will flow when a load is connected between the two materials.

[0102] In practice, as the spherical tip 425 moves along the surface of the square grid 640 due to the vibration of the drill string component, it moves across and along the black and white squares comprising materials A and B, respectively, generating electrical signals at specific coordinates of the grid. Each square can be connected to a signal analysis circuit, which can include voltage and / or current meters, in a manner such that the signals output by the various squares are uniquely identifiable (e.g., by grid coordinates) and distinguishable. Based on the measured signal and the known grid coordinates associated with the square that output the signal, the position of the stylus on the grid at the point in time when the signal was sampled can be determined. The relative displacement of the spherical tip from its resting center position (e.g., in any one or more directions indicated by the directional arrows) can therefore be determined, thereby allowing vibration imaging / mapping of the drill string component. Thus, highly selective real-time vibration contours can be visualized by the distribution of the electrical signal over time over the grid area. Figure 6Bis a side view of movement of stylus tip 425 along the surface of grid 640 in the direction of arrow 645 between grid positions p1 and p7 and corresponding electrical signals 650 generated due to contact and interaction of stylus 425 with the alternating materials comprising checkered screen 640 .

[0103] Figure 6C Another exemplary embodiment of a screen and stylus that may be used in vibration sensor 400 is shown. In this configuration, the screen includes a grid 740 where the squares of the grid are discrete segments and are made of a piezoelectric material, such as quartz, lanthanum gallium silicate, lithium niobate, titanium oxide, lead zirconate titanate, or any other material that exhibits piezoelectricity. When the spherical tip 425 moves along the grid due to vibration of the drill string assembly (e.g., in one or more directions as indicated by the directional arrows), it exerts pressure on the piezoelectric material. The mechanical stress experienced by the piezoelectric material due to this contact results in the generation of electrical charges that can be measured from leads connected to the corresponding unit. The piezoelectric material undergoes a movement of being stressed and released and, therefore, generates electrical pulses due to the movement of the spherical tip relative to the vibration of the drill string assembly. Fig.6D is a side view of the movement of stylus tip 425 along the surface of grid 740 in the direction of arrow 745 and the corresponding pulses generated by stylus 425 contacting and pressing respective portions of the grid at locations p1 and p2.

[0104] As noted, the stylus tip moving along the respective screen provides a signal representative of the amplitude and frequency of the vibration. Figures 7A-7F Exemplary methods for visualizing and analyzing this data in a meaningful way are shown. Fig. 7A , the screen includes a plurality of sensor elements (e.g., squares 775) arranged in a two-dimensional 2D grid 740 with x and y coordinates. To explain the method of locating the measured vibration signal and identifying the individual grid squares, numbers are included on the xy grid axes. During operation, the stylus tip tumbles / rolls along the piezoelectric squares / buttons of the screen. The piezoelectric material is not limited to squares, but can be of any size, shape, pattern, and spacing, depending on the requirements and optimal signal generation.

[0105] The distribution of the stylus tip navigating the 2D space on the screen in response to vibrations can be reconstructed in several ways. The signals generated each time the stylus tip contacts and separates from the piezoelectric square / button can be stored in memory along with specific coordinates on the screen. Note that the signals appear during contact and separation and are repeatable and reconstructible, so multiple signals can be generated at the same coordinates within a given sampling frequency / frame. Fig. 7A As shown by the track overlaying the screen in , the sequence of movements of the stylus tip at a given sampling frequency / frame can be tracked. It should be understood that the track may not be a straight line, but may move more smoothly along the screen. For example, in Fig. 7A In the image, the stylus tip moves from a square with coordinates (0,0), (-1,1), (-2,0), (-1,-1), (0,-1), (0,-2), (1,-2), (0,-1), (1,-1), (1,0), (2,0) to (1,1), creating a spatial and temporal tracking image with visual coherence of vibration. For example, at a given sampling frequency / frame, the farther the track is distributed on the screen, the higher the amplitude of the vibration. For example, Figure 7B Shown is the ratio Fig. 7A Example traces for higher vibration amplitudes. Also, the greater the number of traces at a given sampling frequency / frame, the higher the vibration frequency. For example, Figure 7C Shown is the ratio Fig. 7A Example trajectories for higher vibration frequencies.

[0106] From the sequence, the data can also be reconstructed as heat / contour plots. Fig.7D and Fig. 7E An exemplary heat / contour plot visualization generated from a vibration sensor output is shown. Note that Fig. 7E The distribution of traces on the screen in is the same on both the screen shown on the left and the screen shown on the right, showing similar vibration amplitudes, but the number of traces varies, showing different vibration frequencies. Fig.7D In the example visualization shown, a grid may have contour lines of the response variable, vibration, and a sequence of traces showing the amplitude of the vibration. In a given contour line, the square / button with the trace associated with the vibration on each contour line is highlighted. Similarly, Fig. 7E As shown, blocks / buttons that have multiple tracks at a given time may be represented by a darker color or shading.

[0107] Figure 7C-7E It can also be visualized as time-varying frames, where time can be correlated with the depth of the drilled formation and the drilling mechanics, hydraulics, and rheology to gain insights and optimize drilling parameters to improve drilling efficiency. Figure 7F On the left side of , a sequence of grid images including corresponding vibration trajectories is shown. Figure 7F On the right side of the diagram, a series of thermal / contour plots are shown along with vibration traces. In addition, several frames can also be overlaid on each other, for example for different formations, to better understand the vibration of the drill string components and to optimize the drilling parameters to reduce vibration.

[0108] like Figure 7G As shown, vibrations can also be obtained in all three dimensions. The screen is visualized in 2D, e.g. Figures 7B-7F However, the screen is located around a self-powered active sensing system to acquire vibration data on all three axes. For example, Figure 7G Conceptually shows Figure 5A The four screens shown are equally spaced around the circumference of the vibration sensor 400, thereby enabling the vibration sensor to measure vibrations in three dimensions. Figure 7G A simple explanation is that if there is high vibration primarily in the X axis, this will be shown in screens X1-Z and X2-Z. If there is high vibration primarily in the XZ axis, this will be shown in screens X1-Z and X2-Z. If there is high vibration primarily in the Y axis, this will be shown in screens Y1-Z and Y2-Z. If there is high vibration primarily in the YZ axis, this will be shown in screens Y1-Z and Y2-Z. If there is high vibration primarily in the Z axis, this will be shown in screens X1-Z, X2-Z, Y1-Z, and Y2-Z. In reality, the vibration can be in all three dimensions, and the data visualized from the screens can be used to get a clear picture of the vibration. Furthermore, the number of screens is not limited to four, but can be as many as there are fitted around the SASS.

[0109] Exemplary Speed ​​Sensor Configuration

[0110] refer to Figure 8 -13 and continue to refer Figure 1A -2C, the present invention further describes an exemplary configuration of the speed sensor 100, as described above with reference to Figure 1A A number of different ball bearing 115 and movable member 125 configurations may be used in the velocity sensor 100 in accordance with one or more disclosed embodiments. Figure 8 An exemplary configuration of a speed sensor is shown, such as a speed sensor 100 for measuring revolutions per minute (RPM) during a drilling process. As described above, the speed sensor can include a plurality of sets of opposing top and bottom movable members spaced circumferentially about a groove in a second structure 120, and a rotating annular first structure 110 having top and bottom supports configured to displace the top and bottom movable members when the first structure rotates within the second structure. Figure 8 A close-up cross-sectional side view of a set of isolated top and bottom movable members and top and bottom supports according to an embodiment is provided. In particular, each set of movable members includes a top movable member 825T and a bottom movable member 825B. A section of the first structure 110 is also shown, including a top ball support 815T and a bottom ball support 815B protruding from the top and bottom surfaces of the first structure 120. Figure 8 The positions of movable members 825T and 825B are shown in three stages, namely, before contact, during contact / full compression, and after contact, as ball bearings 815T and 815B move past the movable members in the direction indicated by arrow 845.

[0111] like Figure 8 As shown, the top and bottom movable members 825T and 825B are connected to the second structure 120 by springs 827T and 827B, respectively, and can move up and down within corresponding openings or "channels" 828T and 828B defined in the wall of the second structure 120. When the first structure 110 rotates with the drill string assembly, the top and bottom supports 815T and 815B are in contact with the top and bottom movable members 825T and 825B, respectively. The spring 827 is configured to push the movable member in the direction of the first structure to ensure maximum contact with the opposing support and to compress and expand multiple times during drilling operations.

[0112] exist Figure 8 In the exemplary arrangement shown, the top and bottom ball bearings 815T and 815B are made of or coated with material A, and the movable members 825T and 825B of the second structure 120 are made of material B, where material A and material B have opposite polarities or have polarities as far away from each other as possible. Triboelectric charging is based on the principle that an object becomes charged after it comes into contact with another material through friction. When they come into contact, the charge is transferred from one material to another. Some materials tend to gain electrons, and some tend to lose electrons. If the polarity of material A is higher than the polarity of material B, then electrons are injected from material B into material A. This creates surfaces with opposite charges. When the two materials are separated, due to the imbalance of charge between the two materials, when a load is connected between the two materials, a current will flow. The current continues to flow until the two materials are at the same potential. When the materials move toward each other again, a current will flow, but in the opposite direction. Therefore, this contact and separation movement of the bearings and movable members including materials A and B can be used to generate electrical signals. Figure 8 (Bottom) shows the Figure 8 The relative movement of the support and movable member in the three stages shown generates signals. The time between the electrical signals can be used to infer the RPM of the drill string component. Materials A and B can be made of materials such as polyamide, polytetrafluoroethylene (PTFE), polyethylene terephthalate (PET), polydimethylacrylamide (PDMA), polydimethylsiloxane (PDMS), polyimide, carbon nanotubes, copper, silver, aluminum, lead, elastomer, Teflon, Kapton, nylon or polyester.

[0113] Fig. 9AA close-up cross-sectional side view of a set of isolated movable members and supports according to another exemplary embodiment of a velocity sensor, such as velocity sensor 100, is provided. In particular, each set of movable members includes a top movable member 925T and a bottom movable member 925B. Also shown is a section of the first structure 110, including a top ball support 915T and a bottom ball support 915B protruding from the top and bottom surfaces of the first structure 110. FIG. 9 shows the positions of the movable members 925T and 925B in three stages (i.e., before compression, during compression, and after compression) as the ball supports 915T and 915B move through the movable members in the directions indicated by the arrows.

[0114] Despite Fig. 9A Not shown, the top and bottom movable members are connected to the second structure 120 by springs, and the movable members can be controllably guided to move up and down within corresponding channels provided in the second structure 120.

[0115] According to one or more embodiments, each movable member has a coating of material B on its proximal surface, and the inner end of the channel surrounding these members is coated with material A. As the drill string assembly rotates, the top and bottom ball bearings 915T / B of the first structure 110, for example, made of steel, contact the movable members 925T / B of the second structure 120. The movable members can be made of any material that can operate at high temperatures (>150°C) and high pressures (>5000psi) and has wear resistance suitable for the expected environment. This contact (and the reaction force of the spring) pushes the movable members up / down and down / up in the channel. This causes contact between materials A and B, thereby generating an electrical signal. Fig. 9A (Bottom) shows the signals generated from the movement of the movable member corresponding to the three stages before compression, during compression, and after compression.

[0116] Fig. 9B A close-up isolated view of an exemplary assembly configured to hold a movable member, such as 925T, in place as the movable member, such as 925T, moves within a channel 928T disposed in the second structure 120 is provided. Fig. 9B As shown, two movable tracks 950, each containing a spring 927 and a ball bearing 955 or other suitable bearing device, are arranged to ensure that the movable member returns to the extended position after it is retracted into the closed channel 928T and does not fall out of the closed channel.

[0117] The ball bearing 955 can be mounted on the moving track 950 and contact the movable member 925T (or vice versa) to guide the movement of the movable member. The spring 927 can be connected between the second structure and the movable member. The spring ensures that the movable member retracts and extends, and is configured to ensure that the impact of material B and material B occurs in a controlled manner. The stiffness of the spring can be optimized to maximize the contact and separation movement, and can be of any size and shape to move and constrain material A only in the direction of material B. The spring is preferably constructed in such a way as to minimize the movement delay and experience compression and extension at the same time. The spring also helps the momentum of material A contacting material B, thereby increasing the charge transfer between the two materials. In general, springs follow Hooke's law and generate a restoring force proportional to their displacement. They store mechanical energy in the form of potential energy and release it as a restoring force, thereby generating a constant spring coefficient. The spring can also be adjusted to generate a restoring force that is not proportional to its displacement. Preferably, the spring 927 is not subject to Hooke's law, so they can be made to provide a restoring force according to the needs of the application. The spring 927 that can be used can be a compression spring, a tension spring, a torsion spring, a Belleville spring or any other system made of elastic material.

[0118] Fig. 10A A close-up cross-sectional side view of a set of isolated movable members and supports according to another exemplary embodiment of a velocity sensor, such as velocity sensor 100 , is provided. Fig. 10A The surface of the movable member 1025T / B is shown, particularly the portion that is movable within the second structure 120, and the surface of the closed channel 1028 is coated in an alternating manner with materials A and B. The alternating portions of materials A and B are shown by the alternating black and white segments on the sides of the channel and the sides of the movable part.

[0119] In this configuration, as the drill string assembly rotates, the top and bottom ball bearings 1015T and 1015B of the first structure 110 contact the top and bottom movable members 1025T and 1025B of the second structure 120, pushing the movable members into their respective channels. The sliding movement of the movable members triggers contact between the materials A and B disposed on the movable members and the channels, resulting in the generation of electrical signals. Fig. 10A The positions of the movable members are shown in three stages, namely before compression, during compression and after compression, as the ball bearings move across the movable members in the directions indicated by the arrows. Fig. 10A (Bottom) shows the signals generated from the movement of the movable member throughout the three stages.

[0120] Although Fig. 10A Not shown, but the movable member may also be spring biased, resulting in repeated upward / downward movement of the movable member. Fig. 10B A close-up isolated view of an exemplary assembly configured to hold a movable member, such as 1025T, in place as the movable member, such as 1025T, moves within a channel 1028 disposed in the second structure 120 is provided. Fig. 10B In an exemplary arrangement shown in (a, top), similar to Fig. 9B In the illustrated construction, two movable tracks 1050 are arranged, each of which includes a spring 1027 and a ball bearing 1055 or other suitable bearing device to ensure that the movable member returns to the extended position after it is retracted into the closed channel 1028 and does not fall out of the closed channel. Fig. 10B (b, bottom), another exemplary arrangement is shown in which a single spring 1027B extends between the base of the movable member and the structure 120 and is arranged to ensure that the movable member returns to the extended position after it is retracted into the enclosed channel 1028 and does not fall out of the enclosed channel.

[0121] Fig.11A A close-up cross-sectional side view of a set of isolated movable components and supports according to another exemplary embodiment of a velocity sensor, such as velocity sensor 100, is provided. Fig.11A , the movable members 1125T and 1125B in the second structure 120 have curved surfaces at both the distal / outer end and the proximal / inner end. A piezoelectric material 1122, such as quartz, lanthanum silicate, lithium niobate, titanium oxide, lead zirconate titanate, or any other material exhibiting piezoelectricity, is also disposed in a channel 1128 that closes the movable member toward the inner end. As the drill string assembly rotates, the top and bottom ball bearings of the first structure 110 contact the movable members of the second structure 120, pushing the movable members into the corresponding channels. This movement causes the inner ends of the movable members to contact the piezoelectric material 1122. The mechanical stress to which the piezoelectric material is subjected due to this contact causes the generation of an electrical charge. Although not shown, in the absence of contact with the bearings, the expansion of the spring or piezoelectric material within the channel pushes the movable member outward in the direction of the first structure. The repeated movement caused by the constant rotation of the drill string assembly while drilling enables the piezoelectric material to undergo cycles of being stressed and released, and thus generate an electrical signal. Fig.11A The positions of the movable members are shown in three stages (ie, before, during, and after compression) as the ball bearings move across the movable members in the directions indicated by the arrows. Fig.11A (Bottom) shows the signals resulting from the movement of these movable members throughout the three phases.

[0122] although Fig.11A Not shown, but the movable member may be spring biased, causing the movable member to repeatedly move up / down. Fig. 11B A close-up isolated view of an exemplary assembly configured to hold a movable member, such as 1125, in place as the movable member, such as 1125, moves within a channel 1128 provided in the second structure 120 is provided. Fig. 11B In one exemplary arrangement shown, similar to Fig. 9B The structure is such that two movable rails 1150 are arranged, each of which includes a spring 1127 and a ball bearing 1155 or other suitable bearing device to ensure that the movable member returns to the extended position after it is retracted into the closed channel 1128 and does not fall out of the closed channel.

[0123] Fig.12 A close-up cross-sectional side view of a set of isolated movable members and supports according to another exemplary embodiment of a velocity sensor, such as velocity sensor 100 , is provided. Fig.12 The movable member 1225 is shown connected to the second structure 120 by piezoelectric strips 1222. These strips can be, for example, ceramic nano-ribbons, such as lead zirconate titanate, which generates electricity when bent and stressed. The nano-ribbons can also be wrapped in a flexible elastomer. As the first structure 110 rotates with the rotation of the drill string assembly, the top and bottom supports rotate around and contact the movable member of the second structure 120. This contact causes the member to move up and down / down and up, which generates an electrical signal by bending / stressing the piezoelectric strips. Fig.12 The positions of the movable members are shown in three stages (ie, before, during, and after compression) as the ball bearings move across the movable members in the directions indicated by the arrows. Fig.12 (Bottom) Shown are the signals resulting from the movement of the movable member and the piezoelectric strip throughout the three phases.

[0124] The various exemplary sensor configurations for generating electrical signals described in FIGS. 6-12 can also be used to harvest energy to power other sensors and instruments. In addition, as shown in FIG. 13 , Figure 8-12 The various movable member configurations described in the accompanying drawings may additionally or alternatively be disposed on the inner surface of the second structure 120 .

[0125] Fig.13A 1 is an assembled side view of an exemplary configuration of a speed sensor 1300 for measuring revolutions per minute (RPM) during a drilling process. The speed sensor may include a second structure 1300 having a similar configuration to the second structure 120. The movable member 1325 (from Fig.13AThe movable member extends from a channel 1328 formed in the side wall of the second structure 1300 in the middle direction of the second structure 1300. The sensor 1300 also includes a rotating annular first structure 1310 having a side mounted support 1315, which is configured to displace the movable member as the first structure rotates within the second structure. Fig. 13B Provides various possible configurations, i.e., combinations Figure 8-12 Close-up cross-sectional side views of isolated side-mounted movable members 1325 and side-mounted bearings 1315 in exemplary configurations are shown and described. In each such configuration, during rotation of the drill string assembly, as the ball bearings on the outside surface of the first structure 110 roll along the inside surface of the second structure 120, electricity is generated, triggering the engagement Figure 8-12 Describes the actions of all movable members.

[0126] Example SASS Electronic Device

[0127] Fig.14A A side view of an exemplary SASS, such as SASS 10 , is shown, which includes a ring-shaped flexible electronic circuit 170 and a radio frequency (RF) communication module referred to as an antenna transceiver 180 . Fig.14A The left side of FIG. 1 shows an assembled SASS, wherein the circuit 170 and the antenna transceiver 180 are located inside the second structure 120, and Fig.14A On the right side is an isolated perspective view of the flexible circuit 170 and the antenna transceiver 180. Sensors and instruments other than the vibration and velocity sensors of the SASS that require power to operate and the signal processor can be manufactured on the flexible substrate. The resulting flexible electronic circuit 170 can be composed of metal-polymer conductors, organic polymers, printable polymers, metal foils, transparent film materials, glass, 2D materials such as graphene and MXene, silicon or fractal metal dendrites. The antenna transceiver 180 can include an RF communication module, particularly a processor, that electronically communicates with the flexible circuit 170. The antenna transceiver 180 can also include a compact antenna, which can also be disposed on the flexible substrate and used to send and receive sensor information.

[0128] although Fig.14AThe electronic circuit 170 and the antenna transceiver 180 are shown incorporated into an exemplary configuration of the SASS 10 including the speed sensor 100 but not including the vibration sensor, but it should be understood that the electronic circuit 170 and the antenna transceiver 180 may be similarly included in the SASS 40 including the vibration sensor 400 and the speed sensor 100. Similarly, the electronic circuit 170 and the antenna transceiver 180 may be similarly included in the exemplary configuration of the SASS including the vibration sensor 400 but not including the speed sensor 100.

[0129] Fig. 14B 1 is a conceptual diagram of an exemplary arrangement of electronic components that may be disposed on a flexible circuit 170 or as part of an antenna transceiver 180 of a SASS. According to one or more embodiments, the resulting analog electrical signal obtained by energy harvesting using one or more of a vibration sensor and a velocity sensor may be converted into a digital signal by an analog-to-digital converter 171 disposed on the flexible circuit 170. The signal may be stored in an analog power storage unit 172 disposed on the flexible circuit 170, such as a conventional di-electric capacitor, ceramic, electrolytic, or supercapacitor derated for use at high temperatures. By storing energy in the storage unit, power may be continuously provided to one or more powered sensors 178, instruments, and communication devices such as an antenna transceiver 180. The powered sensor 178 that may be communicatively coupled to the SASS electronic device may be, for example, a low-power temperature, pressure, strain, magnetic field, or electric field sensor.

[0130] Now back to Fig. 14B As described above, the memory unit 172 disposed on the flexible circuit 170 may be configured to supply power to the low-power signal processing circuit 175. The low-power signal processing circuit 175 may be configured to condition data, store it in the local memory 176, and perform power management by interfacing with the energy source (e.g., the active velocity sensor 100 and / or the active vibration sensor 400) and the memory unit 172, thereby delivering appropriate system voltage and load current to the circuit blocks of the flexible circuit 170 in an efficient manner. The low-power signal processing circuit 175 may be a complex programmable logic device (CPLD) based on CMOS, based on a microcontroller, based on a digital signal processor (DSP), based on a field programmable gate array (FPGA), based on an application specific integrated circuit (ASIC), or a system on a chip (SoC).

[0131] The SASS 10 also has an RF communication module, also referred to as a communication module, including an antenna and a transceiver 180. The communication module communicates electronically with the flexible circuit 170. The antenna can be polymer-based, paper-based, PET-based, textile-based, carbon nanotube (CNT)-based, artificial magnetic conductor-based, kapton-based, or nickel-based metamaterial. The transceiver can be configured to employ low-power wireless communication technologies such as low-power WI-Fi, Bluetooth, low-power Bluetooth, ZigBee, etc. Higher frequencies allow better signals and longer transmission distances. However, the system is preferably optimized because attenuation and power requirements are also higher at higher frequencies. Antennas can be directional, omnidirectional, and point-to-point. They can also be planar antennas such as monopole antennas, dipole antennas, inverted antennas, loop antennas, helical antennas, zigzag antennas, and patch antennas. Power management is an important component of the communication module. For example, the communication modules do not have to be continuously active or run simultaneously. The communication module can have an "active" mode, a "standby" mode, and a "sleep" mode. The "active" mode is shorter because the communication module usually has only one short task in the entire system, that is, sending or receiving data, followed by a relatively long "standby" time and a longer "sleep" time. The energy saved in the "standby" and "sleep" times can be used to drive the communication module in the "active" mode.

[0132] Fig. 14C and 14D is a conceptual block diagram illustrating an exemplary configuration of signal processing components of a SASS including a vibration sensor and an additional or alternative velocity sensor. Fig. 14C and 14D Also shown is a sensor data stream from a sensor producing a raw sensor data stream 1470 which passes through the signal processing circuitry of the SASS electronics and reaches a surface where the processed sensor data can be further processed and / or output. The low power signal processing circuitry can be used to store the sensor data with coordinates and create Figures 7B-7F The images shown, for example, may be CMOS based, microcontroller based, digital signal processor (DSP) based, field programmable gate array (FPGA) based, application specific integrated circuit (ASIC) based, complex programmable logic device (CPLD) or system on chip (SoC).

[0133] Fig. 14C and 14DThe exemplary construction of the SASS shown uses an FPGA 1475, however, any suitable low power signal processing circuit may be constructed and used for image reconstruction, such as the low power signal processing circuits described above. FPGA circuits do not require layout, masking, or other manufacturing steps, have simpler design cycles, more predictable project cycles, and field reprogrammability. FPGAs can be reused and are less expensive than ASICs. Because FPGAs can be easily reprogrammed, designs can be loaded into components, tested at high speed in the system, and debugged when necessary. This is ideal for board-level testing, where the FPGA can be constructed to verify the board or components on the board. After testing is completed, the FPGA is reconstructed with the application logic. The FPGA has logic cells / blocks, programmable interconnects, embedded block memory, and input / output blocks to design reconfigurable digital circuits. Therefore, the electrical signal generated by the vibration sensor screen must first be converted from an AC / oscillating form to a DC, which can be performed by an analog-to-digital converter 1471, such as Fig. 14C The raw analog speed sensor signal data stream can be converted similarly.

[0134] The data collected by ADC 1471 allows a large number of channel signals to be sampled simultaneously. The data is then sent to FPGA 1475 where various signal processing algorithms can be implemented to manipulate the data and store it in memory (not shown). The memory can be static random access memory (SRAM), dynamic random access memory (DRAM), or electrically erasable programmable read-only memory (EEPROM) / flash memory as desired. The data is preferably stored in a manner that can be easily recovered at the surface to reconstruct and visualize the data, including, for example Figures 7B-7F Virtual screen image shown to analyze vibration data.

[0135] The piezoelectric cubes of the vibration sensor can also be connected in series or parallel, and the FPGA can be constructed to correlate the changes in the piezoelectric signal with the specific locations of contact and separation that occurred on the screen. The FPGA is the core of the system that controls the data acquisition system, storage, and subsequent data readback. The data can also be processed by a graphics processing unit (GPU) so that the vibration analysis screen can be visualized directly from the input. The GPU has high computational density, high computation per memory access, and can perform many parallel operations, which results in high throughput and latency tolerance. The GPU can also be integrated with a microcontroller or digital signal processor (DSP).

[0136] There are multiple ways to obtain measurement data at the surface. The first method is to download the data once the drill string components are pulled out of the wellbore after the drilling run. For example, the data can be downloaded from the SASS processing unit FPGA 1475 to the display device 1485 through a data communication interface such as Ethernet, Universal Serial Bus (USB), Secure Digital (SD) card, I2C, and Universal Asynchronous Receiver Transmitter (UART). The display device 1485 can be a liquid crystal display (LCD), an organic light emitting diode (OLED), or any display device that can display, for example, a vibration data screen.

[0137] Fig.14D The additional or alternative method SASS shown in the figure can be configured to convert the signals output by the FPGA 1475 back to analog form through a digital-to-analog converter 1481 (DAC) and send them to a radio frequency (RF) module 1480 and transmit the data wirelessly to a display (not shown) through an antenna. Another way to provide measurement data to the ground is to use the method described in this article in conjunction with Fig.18 The distributed sensing system and communication method shown and described, wherein data can be wirelessly transmitted along the drill string, along with the SASS data unit moving from the bottom to the surface and from the surface to the bottom in a relay manner. In addition, in combination with Fig.19 The data carrying capsule shown and described may be used to transmit data from the SASS unit to the surface.

[0138] According to one or more embodiments of the present disclosure, a memory for storing the vibration and / or RPM signal generated by the speed sensing device of the SASS may be provided within the FPGA. Additionally or alternatively, the memory may also be an external storage device shared by the FPGA and the microcontroller, such as Fig.14E shown. Fig.14E is a conceptual circuit diagram showing an exemplary arrangement of SASS components and the process for harvesting energy and power storage to power an FPGA / microcontroller and communications circuits.

[0139] like Fig.14E As shown, in the first stage 1405, power that can be used to power the SASS electronics can be generated by an active speed sensor, such as speed sensor 400. An exemplary set of triboelectric and piezoelectric speed sensors 1440 (e.g., as previously described in conjunction with Fig. 13B The sensor vibration / RPM signals are generated by the FPGA and microcontroller, and are used to generate a charge signal that can be used to determine the speed and power of the SASS electronics. Note that no power is consumed when generating the sensor vibration / RPM signals because they are active sensors. Power is only required for signal conditioning, processing and storage through the FPGA and microcontroller, and wireless transmission through the RF module.

[0140] Both triboelectric and piezoelectric energy harvesting methods require the application and removal of external forces to generate charge. The external force causes the material to be stressed, deformed, and released back to its original shape, as is the case in piezoelectric energy harvesting. In the case of triboelectric energy harvesting, the external force can cause the two materials to come into contact with each other by directly striking each other and separating, or by sliding and separating. In all of these cases, a cycle of stress (short circuit) / release (open circuit) or contact (short circuit) / separation (open circuit) causes charge to flow in one direction and then in the opposite direction, resulting in positive and negative voltage waveforms. The generation of charge and the continuity of the waveform depends on the rotation rate of the drill string components. The charge can be used directly to power flexible electronics, but a more feasible way to optimize this generated electricity is to store the electrical energy so that it can be used as a regulated power source for flexible electronics even in the absence of drill string rotation.

[0141] Therefore, in Fig.14E In the arrangement of the exemplary SASS 1400 shown in , the generated electrical signal must first be changed from an analog signal to a digital signal at stage 1410. This can be achieved by a bridge rectifier circuit 1445, for example using a diode. The output of the ADC can be connected to an energy storage device 1450 for storage at stage 1415. The storage device can be a conventional dielectric capacitor, a ceramic capacitor, an electrolytic capacitor, or a supercapacitor that is rated for use at high temperatures. By storing energy in the capacitor, at stage 1420, the sensor 1442, the processing instrument (e.g., FPGA / microcontroller), and the communication module 1460 can be continuously powered. Compared to batteries, capacitors are easier to integrate into circuits, are generally cheaper, can be purchased off the shelf, and are easier to handle.

[0142] As mentioned above and as Fig.14E As shown, the flexible electronic circuit is arranged so that the vibration and speed sensor 1442 is connected to the FPGA / microcontroller 1455 for receiving sensor data, and the transceiver 1460 is also communicatively coupled to the FPGA / microcontroller for receiving and sending sensor data. Sensor 1442 may include vibration and speed sensors, including speed sensor 1440, although speed sensor 1440 may also be in the Fig.14E Shown separately in.

[0143] The storage unit 1450 supplies power to the FPGA / microcontroller that performs the power management, control, and logic functions of the SASS device 1400, including powering the sensors and transceiver 1460. The transceiver utilizes low-power wireless technologies such as low-power Wi-Fi, Bluetooth, Bluetooth Low Energy, ZigBee, etc. Antennas can be directional, omnidirectional, and point-to-point. They can also be planar antennas such as monopole antennas, dipole antennas, inverted antennas, loop antennas, helical antennas, zigzag antennas, and patch antennas.

[0144] The power consumption of the SASS electronics 1400 is preferably minimized, therefore, power consumption should be carefully controlled. The processor (e.g., FPGA / microcontroller 1455) interprets and processes the information stored in the memory. The processor, memory, transceiver, and antenna all have their own power consumption levels. The sensors do not require power to operate, so there is no power consumption. Therefore, the sensors are able to continuously acquire data and they are continuously "active".

[0145] The FPGA / microcontroller 1455 is preferably constructed to obtain data at a high sampling rate and the transceiver 1460 is designed to send and receive data at a predetermined time or when triggered by an external signal. In addition, since the transceiver requires more energy to send / receive data than the FPGA / microcontroller unit, only data samples analyzed by the FPGA / microcontroller can be sent / received instead of all sensed data to save downhole power. For example, all components in the transceiver module 1460 do not have to be continuously active or operate at the same time. Each component can have an "active" mode, a "standby" mode, and a "sleep" mode. The "active" mode is short because each component generally has only a brief task in the entire system, followed by a relatively long "standby" time and a longer "sleep" time. The energy saved in the "standby" and "sleep" times can be used to drive components in the "active" mode.

[0146] like Fig.14E As shown and described above, the sensor data signals are processed and stored in the storage device 1450. Additionally or alternatively, the sensor signals may be conditioned, processed and stored by the FPGA, for example, in a digital memory. Additionally or alternatively, Fig.14E The exemplary configuration shown in can be adapted so that instead of connecting the output of the bridge rectifier to a capacitor storage device, the output can be sent directly to the FPGA / microcontroller for processing and storage in a memory accessible to the FPGA.

[0147] Powered vibration sensor structure

[0148] Although the vibration sensor 400 includes a self-powered screen 440 according to the exemplary embodiment shown and described in conjunction with FIGS. 4-7 , in one or more embodiments, the vibration sensor may include a powered screen for sensing the position and movement of a stylus thereon. More specifically, Figures 15A-15B An exemplary power supply configuration for a screen used in a vibration sensor of SASS is shown. Fig.15A is a front plan view of a screen including grid 1540, Fig. 15BA cross-sectional side view of a portion of the grid 1540 is provided. As shown, the screen includes a grid 1540 of discrete squares, each grid having an upper electrode 1541 and an opposing lower electrode 1543 separated by a dielectric layer 1542, thereby forming a capacitor. Each square / capacitor can be individually connected to a signal analysis circuit in such a manner that the signal generated by the square / capacitor is uniquely identifiable (e.g., by grid coordinates) and distinguishable. As the spherical tip 425 moves along the screen 1540, i.e., at a position determined by the grid coordinates, the spherical tip 425 is moved along the screen 1540. Fig. 15B It presses on the top electrode 1541 towards the bottom electrode 1543 in the direction indicated by the arrow shown in , and changes the distance between the top and bottom electrodes. This causes a change in the electric field, and thus a change in the capacitance of the capacitor. Based on the change in capacitance, which can be measured using any suitable capacitance meter, and the known grid coordinates of the various squares / capacitors, the position of the stylus on the grid can be determined, and the vibration measured accordingly.

[0149] In yet another arrangement, each individual capacitor defined by the upper electrode square, the lower electrode square and the dielectric layer therebetween may define a capacitor in a corresponding RLC (resistor, capacitor, inductor) circuit, such as Fig.16 . Each RLC circuit may be individually connected to a signal analysis circuit, which may include a resonant frequency meter, in a manner such that the RLCs are uniquely identifiable (e.g., by grid coordinates) and distinguishable. The change in capacitance caused by the spherical tip pressing on the top electrode causes the resonant frequency of the RLC circuit to shift. Based on the resonant frequency shift and the known grid coordinates associated with the respective RLC circuit, the position of the stylus on the grid may be determined and the vibration measured accordingly.

[0150] Figures 17A-17B Another exemplary powering configuration of a screen and stylus is shown that may be used for powering variations of the vibration sensor 400 of the SASS. Fig.17A is a top view of a vibration sensor grid 1740, and Fig. 17B A cross-sectional side view of a portion of a grid 1740 and a circuit diagram connected thereto is provided. As shown, the screen includes a grid 1740 of discrete squares made of a piezoresistive material such as silicon, a carbon nanotube / polymer composite, silicon carbide, graphene, samarium monosulfide, or a Heusler compound. Each piezoresistive square forms part of a Wheatstone bridge circuit 1780 that is connected to a signal analysis circuit, which may include a voltmeter, in a manner such that the signal generated by the corresponding square is uniquely identifiable (e.g., by grid coordinates) and distinguishable. For example, a piezoresistive element / square 1741 is disposed at Fig. 17BAs the spherical tip 425 moves along the screen 1740, i.e., in the circuit diagram of Fig. 17B It presses one or more piezoresistive elements, such as element 1741, in the direction indicated by the arrow shown in FIG. The mechanical strain experienced by the piezoresistive element causes a change in its resistance, which can be detected by a change in the output voltage V of the Wheatstone bridge circuit 1780.

[0151] It should be understood that the above Figures 7A-7F The image reconstruction of the vibration signal shown in is an example that provides a simplified explanation of how to measure the movement of the stylus tip on the screen to obtain information about the amplitude and frequency of the drill string vibration. The principle of operation can be used to obtain any sequence of vibration amplitudes and frequencies. The principle of operation can also be used Fig. 6A , 7A and other vibration structures shown in 15A-17B. For example, in combination with Figures 7A-7F The piezoelectric screen described can be made of Fig. 6A The screen construction shown includes material A / B, Fig.15A The screen structure including upper / lower electrodes shown and Fig.17A The piezoresistive screen shown is constructed instead. Fig. 6A and Fig. 7A In the embodiment shown, the signal generated by contact and separation is used, and Fig.15A and Fig.16 In the embodiment shown, the data of a specific coordinate is recorded by utilizing the capacitance change caused by the electromagnetic field change. Fig. 6A In the example above, since the stylus tip is made of the same material as one of the squares (in this case, black), when the stylus tip moves from the black to the white square, the signal changes from a positive signal or pulse (same materials in contact) to a negative signal or pulse (materials of opposite polarity). As mentioned earlier, each square on the screen has a coordinate, so each signal generated is associated with a coordinate that is used when reconstructing the vibration image. The generation of electrical pulses / waveforms through friction is based on the principle that an object becomes charged when it comes into contact with another material through friction. When they come into contact, the charge is transferred from one material to another. Some materials tend to gain electrons and some tend to lose electrons. If material A has a higher polarity than material B, then electrons are injected from material B into material A. This creates surfaces with opposite charges. When the two materials are separated, due to the imbalance of charge between the two materials, when a load is connected between the two materials, there will be a current flow. The current continues to flow until the two materials are at the same potential. When the materials move towards each other again, there will be a current flow, but in opposite directions. Therefore, this contact and separation movement of materials can be used to generate such as Fig. 6A (Bottom) The electrical pulses shown. Fig.17AIn the vibration sensor construction, contact and separation result in a change in resistance in a Wheatstone bridge circuit, which is used to record data at specific coordinates.

[0152] Furthermore, in any exemplary vibration sensor configuration, the number, sequence, and sampling frequency / frame of screens may be optimized when designing the system. It should also be understood that the vibration information of interest that may be measured using SASS may include relative changes in vibration of drill string components, and need not necessarily include absolute values. At least the relative change in vibration over time is of interest because it can be compared with other available drilling power mechanics, hydraulics, and rheology data to gain insight into the drilling process and optimize operations.

[0153] A SASS-based system for distributed monitoring of downhole parameters

[0154] In accordance with one or more embodiments, a sensor system is provided that includes a plurality of SASS devices positioned along a drill string. Fig.18 1 is a perspective side view of an exemplary SASS-based self-powered system for real-time distributed monitoring of a downhole drilling environment 1800, which includes a plurality of SASSs defining a sensor array. As shown, the SASSs may be of the type that include one or more of a vibration sensor 400 and a velocity sensor 100, as well as other sensors that may be powered by a power storage unit (not shown) of each SASS. SASSs such as SASS 10 and / or SASS 40 may be placed at selected intervals along a drill string assembly 105, for example, to obtain real-time distributed data.

[0155] In the exemplary sensor system 1800, data can be wirelessly transmitted along the drill string, moving between SASS units along the data unit like a relay from the bottom to the surface and from the surface to the bottom. The sensor systems can be placed inside or outside the drill string components, with a certain distance between each other, which can be defined based on the maximum distance that data can be electromagnetically transmitted from one SASS to another. This method of transmitting data along the drill string using SASS is completely independent of drilling fluid flow and is faster than mud pulse telemetry.

[0156] This method of transmitting data along the drill string using SASS is very useful in lost circulation situations, for example, when designing thermosetting lost circulation materials (LCMs) such as resin materials to cure the loss, downhole temperature is required. More specifically, the success of thermosetting LCM resins depends on how accurately the hardening temperature of the viscous LCM matches the downhole temperature. Inaccurate downhole temperatures can cause the resin LCM to solidify within the drill string or not solidify at all downhole and only exist in the lost circulation zone in a gel-like state, thereby failing to plug the fractured formation. Another very important application of having real-time well data is the real-time assessment of kicks in fractured zones. Drilling in deep reservoirs with partial / severe lost circulation is very expensive because the driller is drilling "blind" because there is no real-time data about where the mud is being lost to the formation. Therefore, it is impossible to know the amount and density of mud that needs to be added to the drill string and annulus to control the well, maintain drilling, and ensure that kicks do not reach the surface. Therefore, sensor systems placed along the drill string components provide real-time distributed sensing data that can be used to effectively monitor the well and respond immediately when problems arise.

[0157] Fig.19 is a perspective side view of an exemplary SASS-based self-powered system for real-time distributed monitoring of a downhole drilling environment 1900 shown within a wellbore 1950. Fig.18 The system 1900 includes a distributed SASS sensor array and also includes a memory transport capsule 1910. As noted, individual SASS sensors (e.g., SASS 10 and / or 40) can be used as data storage units along the drill string assembly 105. Thus, the memory transport capsule includes electronics including a processor, a communication transceiver and antenna, and a non-transitory computer readable storage medium within a sealed capsule housing that is suitable for circulating downhole in drilling fluid and withstanding the harsh downhole environment.

[0158] The data storage unit (e.g., non-transitory memory) of each SASS device collects and / or processes the information measured using the onboard sensors and stores it in a local memory. Fig.19 As shown, storage collection mobile capsules 1910 are injected into the well from the surface. As these capsules flow through the storage unit, the data stored in the storage unit can be transmitted to the capsules via the wireless antenna of the SASS. These capsules circulate with the drilling fluid and are recovered at the surface, where the data can be downloaded to a computing device via wired or wireless means for further analysis of the captured information, for example, using a combination of Fig. 20 The control computing device discussed. The memory of the capsules can be erased before they enter the well again so that there is enough space to store data in the next cycle.

[0159] The capsule wirelessly acquires data stored in the SASS memory. In this sense, the capsule wirelessly interfaces with the SASS on the drill string components and lays a platform for the downhole Internet of Things (IoT), opening up a variety of new ways to map and visualize the downhole environment. In addition, the capsules require low-power circuits because they only contain a transceiver, a microcontroller and a power source such as a rechargeable battery, making them suitable for downhole IoT platforms. The battery can be recharged using energy collected by the capsule flowing with the drilling fluid. The power requirements of the capsule are very low for both active and standby modes.

[0160] One of the most efficient ways to combine different modules in a capsule is to segment and stack the modules and interconnect them with short signal paths called through-chip vias or through-silicon vias (TSVs). As a result, there is no need to compromise in material selection and the same chip area can be used for all different modules, enabling seamless inter-layer communication for interoperability of different components. This heterogeneous 3D integration leads to a significant reduction in the overall size of the capsule, and therefore its cost. The capsule also has a protective shell to protect the modules from the harsh downhole environment. These shells can be chemical coatings such as polymers and / or epoxies, resin-based materials, or any material that can withstand continuous exposure to the harsh downhole environment.

[0161] According to one or more embodiments, the SASS electronics provided on the flexible circuit board 170 can utilize a processing-in-memory (PIM) architecture. In a PIM, large amounts of data are calculated, analyzed, and transformed into information and real-time insights by bringing computations closer to the data, rather than moving the data to the CPU. In this way, the data that needs to be transmitted from the SASS to the capsule or another SASS unit and the power required for data transmission can be optimized. For example, for vibration data, data from different screens stored in the SASS can be stored in a memory separated by unique headers to identify the different screens from which the data was obtained. It should be understood that not all vibration screen data must be transmitted, but specific information such as maximum, minimum, average vibration values, or anomalies can still provide valuable data to the driller on the ground.

[0162] The data in the capsule can be stored in static random access memory, where it remains as long as the capsule is powered. They can be integrated on-chip as random access memory (RAM) or cache memory in microcontrollers, application-specific integrated circuits (ASICS), field-programmable gate arrays (FPGAs) and complex programmable logic devices (CPLDs).

[0163] The transceivers in SASS (e.g. Figures 14A-14BThe antenna transceiver 180 shown in ) also preferably supports short-range wireless data transmission with ultra-low latency and ultra-low power requirements. Some methods include ultra-wideband (UWB) communication using short pulses instead of carrier frequencies. Electric and / or magnetic dipole antennas can also be optimized for ultra-low latency and ultra-low power data transmission. Examples include broadband microstrip, broadband monopole antennas on boards, wide slot UWB antennas, stacked patch UWB antennas, tapered slot (TSA) UWB antennas, elliptical printed monopole UWB antennas, metamaterial (MTM) structure UWB antennas, and dielectric resonator antennas (DRA).

[0164] According to one or more embodiments, before data transmission, a command can be sent wirelessly from the ground to change the antenna in the SASS array to a transmission mode to transmit data to a capsule released from the ground and flowing in the well with the drilling fluid. Additionally or alternatively, a group of capsules configured to instruct the antenna to enter a data transmission mode can be deployed before the memory capsule. Then, the data from the SASS array is transmitted to the memory capsule after the initial, guided capsule. In one or more configurations, a specific capsule of each SASS in the array can be configured to communicate only with a specific SASS and / or capture data from a specific SASS. Other data capture methods can also include constructing SASS devices and capsules to achieve ultra-fast wake-up and data transmission times so that the capsule can send a signal to the SASS to change the transceiver state from a "sleep" state to "active" and acquire data. The capsule is configured to "listen" for data transmission to receive and store it in its internal memory and then return to the ground.

[0165] As will be appreciated, the SASS device and / or memory capsule 1910 may be in communication with a control computing system configured to receive and analyze measured sensor data and, optionally, transmit information such as control commands to the SASS device. Fig. 20 is a block diagram illustrating an exemplary configuration of a computing system for processing sensor information received from SASS according to an embodiment of the present invention. As shown, a computing device may be arranged with various hardware and software components for implementing the operation of the exemplary sensor and SASS system configuration. It should be understood that other computing and electronic devices used in various embodiments of the present disclosure may have the following features: Fig. 20 Similar hardware and software components as shown and described.

[0166] Components of computer 2180 include processor 2640, which is Fig. 20 26 is shown as being disposed on a circuit board 2650. The circuit board may include a memory 2655, a communication interface 2660, and a computer-readable storage medium 2065 accessible by the processor 2640. The circuit board 2650 may also include or be coupled to a power supply (not shown) for powering the computing device.

[0167] The processor 2640 and / or circuit board 2650 may also be coupled to a display 2670 for visually outputting information to an operator (user), a user interface 2675 for receiving operator input, and an audio output 2680 for providing audio feedback, as will be appreciated by those skilled in the art. As an example, the processor 2640 may transmit visual signals from the display 2670, such as visualizations representing real-time measured rotational speed and vibration signals measured by one or more SASS devices 10 and / or 40 provided along the drill string 105. While various components are depicted as being separate from or as part of the circuit board 2650, it will be appreciated that these components may be arranged in various configurations.

[0168] The processor 2640 is used to execute software instructions that may be loaded into the memory 2655. The processor 2640 may be implemented using multiple processors, a multi-processor core, or some other type of processor. The memory 2655 is accessible by the processor 2640, so that the processor 2640 can receive and execute instructions stored on the memory 2655 and / or computer-readable storage medium 2065. The memory 2655 may be implemented using, for example, a random access memory (RAM) or any other suitable volatile or non-volatile computer-readable storage medium. In addition, the memory 2655 may be fixed or removable.

[0169] Computer readable storage medium 2065 may also take various forms, depending on the particular implementation. For example, computer readable storage medium 2665 may include one or more components or devices, such as a hard drive, flash memory, a rewritable optical disk, a rewritable tape, or some combination thereof. Computer readable storage media may also be fixed or removable or remote, such as a cloud-based data storage system (remote memory or storage configuration not shown). For example, a computer readable storage medium may be used to maintain a database 2085 that stores information related to the capture of measurement data, measurement data captured for various sensors on a SASS device, and / or data used or generated when performing operations and implementing aspects of the systems and methods disclosed herein.

[0170] One or more software modules 2688 are encoded in the memory 2655 and / or the computer-readable storage medium 2665. The software modules 2688 may include one or more software programs or applications having a computer program code or a set of instructions executed by the processor 2640. Such computer program codes or instructions for performing operations and implementing aspects of the systems and methods disclosed herein may be written in any combination of one or more programming languages. Although the software modules 2688 are stored locally in the computer-readable storage medium 2065 or the memory 2655 and executed locally in the processor 2640, the processor 2640 may interact with a remote computing device or even a downhole SASS device via the communication interface 2660 and via a local or wide area network to perform calculations, analysis, control, and / or any other operations described herein.

[0171] During the execution of software module 2685, processor 2640 is configured to perform various operations described herein, including but not limited to analyzing sensor data, controlling SASS devices, and operating the drill string based on the measured sensor data. Software module 2688 may include code for implementing the aforementioned steps and other steps and actions described herein, such as but not limited to: sensor data capture module 2670, which configures computing device 2150 to capture and analyze sensor data measured using, among other things, vibration sensor 400, velocity sensor 100, and any other sensor device on SASS; and communication module 2678, which configures processor 2640 to communicate with a remote device (e.g., SASS disposed on drill string and memory capsule 1910) via a communication connection such as a communication network or any wired or wireless electronic communication connection.

[0172] The software module 2685 and the program code of one or more non-transitory computer-readable storage devices (eg, memory 2655 and / or computer-readable storage media 2665) may form a computer program product that may be manufactured and / or distributed according to the present disclosure.

[0173] It should be understood that various combinations, substitutions and modifications of the present disclosure can be designed by those skilled in the art. The present disclosure is intended to include all such substitutions, modifications and variations that fall within the scope of the present application.

[0174] It should be understood that like reference numerals in the drawings denote like elements throughout the drawings, and not all embodiments or arrangements require all components and / or steps described and illustrated with reference to the drawings.

[0175] The terms used herein are used only for the purpose of describing specific embodiments and are not intended to limit the present disclosure. As used herein, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that when used in this specification, the terms "comprises" and / or "comprising" specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or combinations thereof.

[0176] In addition, the phraseology and terminology used herein are for descriptive purposes and should not be regarded as limiting. The use of "including," "comprising," or "having," "comprising," "involving," and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.

[0177] The subject matter described above is provided by way of illustration only and should not be construed as limiting. Various modifications and changes may be made to the subject matter described herein without following the exemplary embodiments and applications shown and described, and without departing from the true spirit and scope of the invention contained in this disclosure, which is defined by the embodiments in this application and structures and functions or steps equivalent to these embodiments.

Claims

1. A self-powered active sensing system for a downhole drilling environment, the system comprising: A speed sensor is used to measure the rotation speed of the drill string. The speed sensor has: A first structure in the shape of a ring, the first structure in the shape of a ring configured to be attached around a portion of a drill string, wherein the first structure extends circumferentially around the drill string and rotates around an axis of rotation of the drill string, the first structure comprising: a support extending from an outer surface of the first structure; a housing disposed around the first structure and a portion of the drill string, wherein the housing comprises: an inner wall defining a hollow central opening of sufficient diameter to extend a drill string therethrough, wherein the inner wall is shaped to define an annular groove extending circumferentially about the central opening, wherein the ring is at least partially received within the annular groove and is rotatable relative to the housing, and a movable member received within a recess formed in the inner wall and extending into the annular groove, wherein the movable member is opposed to a support, wherein the support is configured to contact the movable member when the first structure is rotated relative to the housing, and wherein the movable member is configured to translate into the recess as a result of contact with the support; and Wherein the movable member is configured to generate an analog electrical signal representing a rotational speed of the drill string based on contact between the support and the movable member.

2. The system according to claim 1, further comprising: a plurality of supports extending from an outer surface of the first structure, wherein the supports are spaced circumferentially around the first structure; and A plurality of movable members extend from an inner surface of the housing facing the outer surface of the first structure, wherein the movable members are circumferentially spaced apart.

3. The system according to claim 1, wherein: The movable member is configured to generate an electrical signal indicative of a rotational speed of the drill string in the absence of external power.

4. The system according to claim 1, wherein: At least a distal end of the movable member includes a first material and the support includes a second material, wherein the first material and the second material have one or more of opposite polarities and away polarities.

5. The system according to claim 1, wherein: The movable member comprises a first material, and wherein the portion of the inner wall defining the recess comprises a second material, wherein the first material and the second material have one or more of opposite polarities and away polarities.

6. The system according to claim 1, wherein: At least one proximal end of the movable member includes alternating materials, which include a first material and a second material, and wherein the portion of the inner wall defining the recess includes alternating materials, which include a first material and a second material, wherein the first material and the second material have one or more of opposite polarity and away polarity.

7. The system of claim 1, further comprising: A piezoelectric material is disposed within the recess and is configured to generate an electrical charge when contacted by the proximal end of the movable member, and wherein an electrical circuit is coupled to the piezoelectric material.

8. The system of claim 1, further comprising a spring disposed within the recess, wherein the spring urges the movable member in a direction toward the support.

9. A self-powered active sensing system for a downhole drilling environment, comprising: A vibration sensor is used to measure the vibration of a drill string, the vibration sensor comprising: A housing shaped to extend circumferentially around a drill string so as to allow the drill string to rotate within a central opening of the bore, wherein the housing comprises: an inner wall within the housing, the inner wall being shaped to define an annular cavity extending circumferentially through the housing, and a screen disposed on a surface of an inner wall defining the annular cavity; A substantially annular ring structure, wherein the ring structure is mounted within and coaxial with the annular cavity, the ring structure comprising: a spherical support extending from an outer surface of the ring structure facing the screen, wherein the spherical support is configured to contact the screen, and a plurality of springs supporting the ring within the annular cavity of the housing, wherein the springs are configured to maintain the spherical bearing in contact with the screen and to enable the spherical bearing to move across the screen in one or more directions in response to vibration forces acting on the housing; and wherein the screen is configured to generate simulated electrical vibration signals based on movement of the spherical bearing across the screen in one or more directions, and wherein the simulated electrical vibration signals represent the position of the spherical bearing on the screen and thus represent vibrations of the drill string.

10. The system according to claim 9, wherein: The screen comprises a two-dimensional array of discrete segments having a first material and discrete segments comprising a second material arranged in an alternating manner, wherein the first material and the second material have one or more of opposite polarities and away polarities, and wherein the spherical supports comprise the first material.

11. The system according to claim 9, wherein: The screen includes: An outer surface defined by discrete segments comprising piezoelectric material arranged in a two-dimensional array, wherein each segment in the array is part of an electrical circuit, each segment being configured to generate an electrical charge when contacted by the spherical support.

12. The system according to claim 11, further comprising: One or more Wheatstone bridge circuits, wherein each discrete segment defines a resistor within a Wheatstone bridge circuit of the one or more Wheatstone bridge circuits.

13. The system according to claim 9, wherein: The screen includes: A two-dimensional array of capacitor segments, each capacitor segment having: The outer surface layer defined by the upper electrode, The lower electrode, and a dielectric layer separating the upper electrode and the lower electrode, wherein the outer surface is configured to move toward the lower electrode when contacted by the spherical support, thereby changing the capacitance; and Wherein the circuit is electrically coupled to the capacitor segments, and wherein the circuit is configured to measure changes in capacitance of the segments and generate a signal indicative of a position of the spherical bearings on the array and representative of vibrations of the drill string.

14. The system according to claim 9, wherein: The screen is self-powered and is configured to generate electrical signals without receiving power from an external power source.

15. A self-powered active sensing system, further comprising: A housing disposed circumferentially around a portion of a drill string, wherein the housing comprises: an inner wall defining a hollow central opening of sufficient diameter to extend a drill string therethrough, wherein the inner wall of the housing is shaped to define an annular groove extending circumferentially about the central opening, and an inner wall within the housing, the inner wall being shaped to define an annular cavity extending circumferentially through the housing, and wherein the housing is further configured to accommodate a speed sensor for measuring a rotational speed of the drill string and a vibration sensor for measuring a vibration of the drill string; The speed sensor is used to measure the rotation speed of the drill string. The speed sensor has: a first structure in the shape of a ring, the first structure in the shape of a ring configured to be attached around the portion of the drill string, wherein the first structure extends circumferentially around the drill string and rotates around an axis of rotation of the drill string, the first structure comprising: a support extending from an outer surface of the first structure, and wherein the ring is at least partially received in an annular groove defined by an inner wall of the housing and is rotatable relative to the housing; and a movable member received in a recess formed in the inner wall of the housing and extending into the annular groove, wherein the movable member is opposed to the support, wherein the support is configured to contact the movable member when the first structure rotates relative to the housing, and the movable member is configured to translate into the recess due to contact with the support, and wherein the movable member is configured to generate an analog electrical signal representing a rotational speed of the drill string based on contact between the support and the movable member; and The vibration sensor is used to measure the vibration of the drill string, and the vibration sensor comprises: a screen disposed on a surface of an inner wall defining an annular cavity within the housing; A substantially annular ring structure, wherein the ring structure is mounted within and coaxial with the annular cavity, the ring structure comprising: a spherical support extending from an outer surface of the ring structure facing the screen, wherein the spherical support is configured to contact the screen, a plurality of springs supporting the ring within the annular cavity of the housing, wherein the springs are configured to maintain the spherical bearing in contact with the screen and to enable the spherical bearing to move across the screen in one or more directions in response to vibration forces acting on the housing, and wherein the screen is configured to generate simulated electrical vibration signals based on movement of the spherical bearing across the screen in one or more directions, and wherein the simulated electrical vibration signals represent the position of the spherical bearing on the screen and thus represent vibrations of the drill string.

16. The self-powered active sensing system of claim 15, further comprising: An electronic circuit is disposed in the housing and electrically connected to the vibration sensor and the speed sensor, wherein the electronic circuit comprises: an electrical storage device, wherein the analog electrical vibration signal and the analog electrical signal representing the rotational speed of the drill string are stored on the electrical storage device; and A communication transceiver and an antenna are disposed within the housing and communicatively connected to the electronic circuit.

17. The self-powered active sensing system of claim 16, wherein the electronic circuit further comprises: an analog-to-digital signal converter configured to convert an analog electrical signal and an analog electrical vibration signal representing a rotational speed of the drill string into corresponding digital signals; and A non-transitory computer-readable storage medium is configured to store a corresponding digital signal.

18. The self-powered active sensing system of claim 16, wherein the power storage device is one or more of a dielectric capacitor, a ceramic capacitor, an electrolytic capacitor, and a supercapacitor.

19. The self-powered active sensing system of claim 16, further comprising a powered sensor communicatively coupled to the electronic circuit, wherein the powered sensor is constructed to measure one or more parameters of a downhole environment and a drill string, wherein the electronic circuit is constructed to provide energy stored in the power storage device to the powered sensor.

20. The self-powered active sensing system of claim 19, wherein: The powered sensor is one or more of a low power temperature sensor, a pressure sensor, a strain sensor, a magnetic field sensor, and an electric field sensor.

21. A self-powered system for real-time distributed monitoring of a downhole drilling environment, the system comprising: The plurality of self-powered active sensing systems of claim 16, wherein the plurality of self-powered active sensing systems are distributed along the length of the drill string.

22. The system of claim 21, wherein: The electronic circuit provided in each of the plurality of self-powered active sensing systems further includes a communication module, wherein the communication module is configured to wirelessly transmit information associated with the stored corresponding digital signal to an adjacent self-powered active sensing system device in the self-powered active sensing system using the transceiver and the antenna.

23. The system of claim 21, further comprising: A plurality of storage transport capsules configured to be circulated downward through the borehole and returned to the surface, wherein each storage transport capsule comprises a sealed outer casing, and internal electronics including a non-transitory computer-readable storage medium and a wireless transceiver and antenna, and wherein each memory transmission capsule is configured to receive measurement data wirelessly transmitted from one or more self-powered active sensing systems and store the received data in its non-transitory computer-readable storage medium; and The electronic circuit provided in each of the plurality of self-powered active sensing systems further comprises a communication module, wherein the communication module is configured to wirelessly transmit the stored measurement data to any adjacent memory transmission capsule using the transceiver and the antenna.

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