Autonomous downhole robotic transport platform

Abstract

A modular mobile platform has extendable and retractable tractor pads for engaging the walls of a downhole environment. The extendable and retractable tractor pads allow the platform to successfully navigate longitudinally through the downhole environment. The platform is made up of a plurality of different modules that are longitudinally removably interconnected together. Each module has at least one specific function, such as sensing, navigation, mobility, control, communication, power, or combinations thereof. The platform has longitudinally directed detectors for detecting forward or reverse directions in which the platform is to travel. A platform front end having sensors at its forward end is articulated to laterally navigate the mobile platform through a breach in the downhole environment. A system and a method use the modular mobile platform.

Description

Technical Field

[0001] This disclosure generally relates to geological drilling and downhole processes, and more specifically, to modular mobile platforms configured to travel through and navigate different downhole environments, and to systems and methods for using such modular mobile platforms. Background Technology

[0002] In geological environments, such as downhole wells or pipelines, it is advantageous to use robots or mobile platforms equipped with electronically based instruments to explore the environment and inspect the well walls. However, the longitudinal movement of robots downhole presents challenges to known robots because the lateral width within such environments can vary considerably. Consequently, the robot's sides may scrape or collide with the walls, potentially damaging the robot and its instruments.

[0003] Many robots in the prior art also have fixed structures, such as a housing for holding a set of fixed motors for movement, and a set of fixed instruments for monitoring and inspecting the downhole environment. However, once such a robot is built, it cannot be modified without disassembling it, if possible. Therefore, robots in the prior art are limited by the motors and instruments included during their construction.

[0004] Some robots in the prior art are configured in a fixed, elongated form to travel up or down in downhole environments that are typically longitudinally extended. However, some downhole environments may have branches and turns, thus preventing the robot's fixed, elongated configuration from navigating these branches and turns.

[0005] Known robots already in use in downhole environments have other limitations. This disclosure addresses these limitations. Summary of the Invention

[0006] According to embodiments consistent with this disclosure, a modular mobile platform has an extendable and retractable traction contact for engaging the walls of a downhole environment. This traction contact allows the platform to successfully navigate longitudinally through the downhole environment. Furthermore, the platform can consist of multiple different modules removably interconnected longitudinally. Each module may have specific functions, such as sensing, navigation, movement, control, communication, and power. The platform may have a generally longitudinally oriented detector for detecting the forward or backward direction through which the platform will travel. This disclosure also includes systems and methods for using such a modular mobile platform. The platform may also be elongated and capable of hinged laterally relative to its longitudinal axis to allow for lateral movement.

[0007] In embodiments consistent with this disclosure, a mobile platform capable of navigating in a downhole environment includes: a plurality of interconnected modules, including a navigation module located at the front end of the modules, wherein the navigation module is configured by a processor executing code therein to detect features of the downhole environment and guide the plurality of interconnected modules, including the mobile platform, toward features within the downhole environment. The navigation module includes: an articulated arm; a sensor disposed at the front end of the articulated arm and configured to detect features of the downhole environment; and an actuator connected to bend the articulated arm in a selected lateral direction; a computing module among the plurality of interconnected modules, the computing module being configured by a processor executing code therein to determine a first width of an approaching portion of the downhole environment based on the features; and a drive module among the plurality of interconnected modules, the drive module having an extendable and retractable traction contact; wherein the computing module is further configured to: control the drive module to extend or retract the traction contact such that the drive module has a second width less than the first width, thereby assembling the mobile platform in the approaching portion in a selected direction, and control the drive module to drive the traction contact, thereby moving the mobile platform in the approaching portion in the selected direction. The navigation module, computing module, and drive module are linearly interconnected.

[0008] In some embodiments consistent with this disclosure, the navigation module, computing module, and drive module are removably interconnected. In some embodiments, each of the navigation module, computing module, and drive module has a housing that is substantially cylindrical with a longitudinal axis of the respective module. In the same or different embodiments, the navigation module, computing module, and drive module are interconnected with the longitudinal axes of the respective modules, which are substantially aligned to form a mobile platform and define a substantially cylindrical shape along the longitudinal axis of the mobile platform.

[0009] In some embodiments consistent with this disclosure, the sensor transmits a detection signal in a forward direction to detect features in the downhole environment, such as along a selected lateral direction. The detection signal includes ultrasonic waves. The computing module uses wireless signals to control the drive module.

[0010] In another embodiment consistent with this disclosure, a mobile platform capable of navigating in a downhole environment includes: a plurality of interconnected modules, including a navigation module located at the front end of the modules, wherein the navigation module is configured by a processor executing code therein to detect features of the downhole environment and guide the plurality of interconnected modules, including the mobile platform, toward the features within the downhole environment, the navigation module including: an articulated arm; a sensor disposed at the front end of the articulated arm and configured to detect the features; and an actuator connected to bend the articulated arm in a selected lateral direction; and a computing module among the plurality of interconnected modules, the computing module being configured by a processor executing code therein to determine The navigation module comprises a first width of the upcoming portion in a selected lateral direction; and a drive module among multiple interconnected modules, the drive module having an extendable and retractable traction contact surface; wherein the computing module is further configured to: control an actuator to bend a hinged arm in a selected lateral direction to guide the hinged arm toward the upcoming portion of the downhole environment; control the drive module to extend or retract the traction contact surface to give the drive module a second width less than the first width, thereby assembling the mobile platform in the upcoming portion in the selected direction; and control the drive module to drive the traction contact surface to move the mobile platform in the upcoming portion in the selected direction. A sensor emits a detection signal in the lateral direction for detecting the feature. The detection signal includes ultrasonic waves. The navigation module, computing module, and drive module are interconnected. The navigation module, computing module, and drive module can be removably interconnected.

[0011] In some embodiments consistent with this disclosure, each of the navigation module, computing module, and drive module has a housing that is substantially cylindrical with a longitudinal axis of the respective module. In the same or different embodiments, the navigation module, computing module, and drive module are interconnected with the respective module longitudinal axes, which are substantially aligned to form a mobile platform and define a substantially cylindrical shape along the longitudinal axis of the mobile platform. The traction contact surface extends or retracts laterally relative to the longitudinal axis of the mobile platform. The computing module controls the drive module using wireless signals.

[0012] In another embodiment consistent with this disclosure, a method includes interconnecting a plurality of modules, the plurality of modules including a computing module, a driving module, and a navigation module at the front end of the modules, wherein the navigation module is configured by a processor executing code therein to detect features of a downhole environment and guide the plurality of interconnected modules, including a mobile platform, to the features within the downhole environment, the navigation module including: an articulated arm; a sensor disposed at the front end of the articulated arm and configured to detect the features; and an actuator connected to bend the articulated arm in a selected lateral direction; wherein the computing module is configured by a processor executing code therein to determine a first width of an upcoming portion in the selected direction, wherein the driving module... The block has an extendable and retractable traction contact surface; wherein, the computing module is further configured to: control the drive module to extend or retract the traction contact surface such that the drive module has a second width less than a first width, thereby assembling the mobile platform into the upcoming portion in a selected direction, and control the drive module to drive the traction contact surface to move the mobile platform in the upcoming portion in the selected direction; deploy the mobile platform into the downhole environment; detect characteristics of the downhole environment; determine a first width of the upcoming portion of the downhole environment; move the traction contact surface of the drive module to assemble the mobile platform into the upcoming portion; and advance the mobile platform into the upcoming portion of the downhole environment. Moving the traction contact surface includes extending the traction contact surface from the drive module or retracting the traction contact surface toward the drive module before advancing the mobile platform into the upcoming portion of the downhole environment.

[0013] According to this disclosure, any combination of the various embodiments and implementations disclosed herein can be used in further embodiments. These and other aspects and features can be understood from the following description of certain embodiments presented herein, based on this disclosure, the accompanying drawings, and the claims. Attached Figure Description

[0014] Figure 1 This is a top front perspective view of a mobile platform having a traction contact surface in an extended configuration, according to one embodiment.

[0015] Figure 2 yes Figure 1 A side view of the mobile platform, in which one set of traction contact surfaces are in a fully extended configuration, while another set of traction contact surfaces are in a partially extended configuration.

[0016] Figure 3 Is in Figure 1 A front view of the fully extended mobile platform.

[0017] Figure 4 This is a top front perspective view of the drive module with the traction contact surface extending out.

[0018] Figure 5 This is a side sectional view of the rear sensor module.

[0019] Figure 6 yes Figure 5 A side view of one end of the rear sensor module.

[0020] Figure 7 This is a side view showing the detection range of the front sensor module.

[0021] Figure 8 This is a top front perspective view of the front sensor module with an articulated arm.

[0022] Figure 8A This is a top front perspective view of the actuator of the articulated arm.

[0023] Figure 8B This is a top front perspective view of the other actuator of the articulated arm.

[0024] Figure 9 yes Figure 8 A side view of the articulated arm moving laterally in a crack in a downhole environment.

[0025] Figure 10 This is a flowchart of a method for operating a mobile platform.

[0026] Note that the accompanying illustrations are illustrative and not necessarily drawn to scale. Detailed Implementation

[0027] Example embodiments consistent with the teachings included in this disclosure relate to a modular mobile platform capable of traversing various downhole environments, including those with branch and steering passages located on the side of the main borehole, and systems and methods for using such a modular mobile platform.

[0028] like Figure 1-9As shown, the mobile platform 10 includes multiple interconnected modules 12-32 for traversing downhole environments with different geometries. Each module 12-32 has its own housing, the dimensions of which generally make the overall shape of the mobile platform 10 suitable for movement through boreholes. More specifically, the mobile platform 10 defines a generally cylindrical robot, as shown, wherein the discrete housings of the individual modules can each be cylindrical and elongated along the longitudinal axis of the mobile platform 10. Modules 12-32 constitute the mobile platform 10 when interconnected end-to-end with one module from another. Modules 12-32 can be removably connected such that they are fixed together to form the platform 10. This cylindrical, elongated configuration of the platform 10 and its modules 12-32 has a common longitudinal axis and a minimum lateral width, for example, about 2.585 inches (about 6.566 cm). This minimum lateral width allows the platform 10 to traverse the downhole environment, provided that the width of the current portion of the downhole environment is greater than the width of the mobile platform 10.

[0029] The mobile platform 10 carries instruments suitable for navigation and inspection of downhole environments. (Reference) Figure 1 The modules may include a front sensor module 12, a first drive module 14, a first computing module 16, a second drive module 18, a first power module 20, a third drive module 22, a second power module 24, a fourth drive module 26, a second computing module 28, a fifth drive module 30, and a rear sensor module 32, which is attached to a tether 34 from a drilling rig on the Earth's surface. The front sensor module 12 is located at the front end of the platform 10, and the rear sensor module 32 is located at the rear end of the platform 10. The rear sensor module 32 can supply power from the drilling rig to at least the fifth drive module 30 via the tether 34. In different configurations, embodiments may have additional or fewer modules arranged; however, according to a significant aspect of this disclosure, at least the front sensor module 12 is included in all embodiments and is hinged to at least one other module (if not multiple additional modules) to form a given embodiment of the mobile platform 10.

[0030] The front sensor module 12 and the rear sensor module 32 may include housings with openings through which the respective sensors can detect the downhole environment 36 and local geological geometry at the front or rear end of the platform 10, such as... Figure 2 As shown, each of the modules described herein is associated with a hardware processor and a memory unit containing the code. The code is loaded from memory into the processor and configures the processor to perform the functions of the corresponding module, such as the front sensor module 12 and the rear sensor module 32.

[0031] The following is for reference. Figure 6-9 For a more detailed description of the front sensor module 12, please refer to the following. Figure 5-7The rear sensor module 32 is described in more detail. Using sensors, such as sensor 38, platform 10 can operate in autonomous mode under the control of code executed in one or more processors to move forward and backward and navigate through the downhole environment 36, having features such as Figure 2 and 9 The arrangement is shown. Furthermore, the sensor can detect contraction 40 or expansion 42 within the downhole environment 36, such as... Figure 2 As shown, the traction contact can be retracted, such as the traction contact on drive module 14, or it can be extended, such as the traction contact on drive module 18. This retracted or extended traction contact engages the wall at contraction 40 or expansion 42, respectively, to ensure friction between the traction contact and the wall. Driving the traction contact then moves at least drive modules 14, 18 by contraction 40 or expansion 42, and thus moves the mobile platform 10 through the downhole environment 36.

[0032] Alternatively, data from sensors on the front sensor module 12 and rear sensor module 32 can be relayed to an operator outside the well, such as to their location on the Earth's surface. Thus, platform 10 can operate in a semi-autonomous mode, in which the operator processes sensor data and instructs platform 10 to move forward or backward within the downhole environment via communication transmitted through tether 34. In this alternative arrangement, platform 10 operates under the control of code executing in one or more processors and further complies with any commands that may have been received from the user. In another alternative embodiment, consisting of at least one processor executing locally on platform 10, the operator instructs platform 10 to locally control its movement using signals provided to computing modules 16, 28. Such signals may be radio waves.

[0033] Refer again Figure 1 Each of the drive modules 14, 18, 22, 26, and 30, such as drive module 14, may include a traction contact surface 44, such as... Figure 3-4 As shown, it can retract or extend laterally relative to the longitudinal axis. Figure 1-2In an example embodiment, the retraction and extension of the traction contact 44 and the power operation of the traction contact 44 are controlled by computing modules 16 and 28. Computing modules 16 and 28 are associated with a hardware processor and a memory unit containing code, which may be the same processor and memory used by other modules, or different processors and memories. The computing modules implement code loaded from memory that configures the processor to perform the functions of computing modules 16 and 28, including the control of one or more drive modules. In an alternative embodiment, because platform 10 is modular, platform 10 can accommodate any number of drive modules, such as drive modules 14, 18, 22, 26, and 30 required for a specific application of platform 10 in a downhole environment. For example, a module may be connected to one computing module for every two drive modules, such as a first computing module 16 associated with drive modules 14 and 18, and a second computing module 28 associated with drive modules 26 and 30. The computing module controls the associated drive module adjacent to it. Alternatively, the computing module may be associated with and control a drive module not adjacent to that particular computing module. For example, as Figure 1 As shown, the drive module 22 is associated with and controlled by the nearest computing module, such as computing module 16.

[0034] In one embodiment, each drive module may be powered by an adjacent power module, such as power module 20 which supplies power to adjacent drive modules 18, 22, and power module 24 which supplies power to adjacent drive module 26. Alternatively, drive module 22 may receive power from power module 24. Power modules 20, 24 have batteries that supply power to their respective drive modules. Any drive module not adjacent to a power module may include a battery within its respective drive module. Such a battery may be rechargeable. Alternatively, for any drive module attached to the rear sensor module 32, such as Figure 1 The drive module 30 can be powered directly from the tether 34 via the rear sensor module 32. In another alternative embodiment, the power supplied from the tether 34 via the rear sensor module 32 can charge a rechargeable battery inside the drive module 30. Power can be transmitted to each of the individual modules via electrical connections associated with the interconnections of any particular arrangement of the modules.

[0035] As described above, depending on the specific application of the deployed mobile platform 10, various modules with specific functions can be removably interconnected. Specific applications may include cameras and other types of detectors, laterally oriented on the computing module, for inspecting the walls of wells or pipes. Alternatively, the lateral cameras and detectors may be included in a detection module with a different configuration than the computing module. Alternative applications may include a repair module with a laterally retractable and extendable arm, having code executing in its processor that enables tools associated with the repair module to engage and repair the walls of wells or pipes, such as by welding, sealing, or supporting the borehole wall or pipe material.

[0036] exist Figure 3-4 In the illustrated embodiment, each drive module, such as drive module 14, has three actuator contacts 44 mounted on the retractable and extendable arm 46. Figure 3-4 As shown, the three puller contacts of a particular drive module are spaced apart, for example, by about 120° around the longitudinal axis. This angular difference between the contacts of a particular drive module provides greater stability to that drive module as the arm, including the contacts of the respective drive module, extends and is preloaded onto the downhole wall. In an alternative embodiment, the drive module may have two puller contacts spaced apart by about 180° around the longitudinal axis. In another alternative embodiment, the drive module may have four puller contacts spaced apart by about 90° around the longitudinal axis. In yet another alternative embodiment, a drive module having at least two puller contacts may have such puller contacts spaced apart at different angles. In this example of different angle configurations, alternatively, Figure 3-4 The first drive module 14 in the middle has three traction contact surfaces 44, which may have two traction contact surfaces spaced about 180° apart around the longitudinal axis, and a third traction contact surface spaced about 90° apart from the other two traction contact surfaces around the longitudinal axis, forming a "T"-shaped configuration of the traction contact surfaces.

[0037] In such Figure 1 In the illustrated embodiment, at least one drive module 18 is configured to rotate the traction contact surface by an angle, such as approximately 60°, relative to the longitudinal axis and relative to the traction contact surface of the first drive module 14. This angular difference between the contacts of the different drive modules provides greater stability to the entire platform 10 as the arm including the contact surface extends and is preloaded onto the downhole wall.

[0038] Each drive module 14, 18, 22, 26, 30 has two subsystems: a preloading system and a drive system. The drive system uses worm gear drives to actuate the contact surfaces on each module 14, 18, 22, 26, 30, allowing the platform 10 to move longitudinally forward and backward. The drive modules are associated with a hardware processor and a memory unit containing code. The code is loaded from memory into the processor and configures the processor to implement the functions of drive modules 14, 18, 22, 26, 30, or it may be associated with other modules, depending on the specific implementation method.

[0039] Under the control of the code executing to implement each corresponding drive module, each contact surface on the arms of drive modules 14, 18, 22, 26, and 30 can be independently retracted and extended, although the contact surfaces of a particular drive module are connected together by a worm gear drive to achieve radial symmetry. Also under the control of the code executing to implement each corresponding drive module, the preloading system controls the lateral distance between platform 10 and the downhole wall by extending and retracting the arms of each drive module. In the illustrated embodiment, the preloading system and the drive system use a single motor to actuate each subsystem. Under the control of the code executing each corresponding drive module, the preloading motor rotates the lead screw and applies preloading to the contact surface via the radially moving arm. Furthermore, under the control of the code executing each corresponding module, the drive motor drives the moving platform 10 to move forward or backward in a direction parallel to the longitudinal axis of the moving platform via the moving contact surface.

[0040] The preloading subsystem allows the arm with contact surfaces to extend to accommodate various diameters that the platform 10 is expected to pass through, and to retract to hide itself when passing through narrow pipes such as XN joints. The preloading subsystem radially moves the three contact surfaces toward / away from the longitudinal axis. On each drive module, all three contact surfaces are coupled together and move together. The contact surfaces cannot extend or retract individually. However, the preloading subsystem for each drive module allows all three puller contact surfaces to extend or retract independently of the other drive modules of the platform 10.

[0041] At least two drive modules are required to pass through the XN joint, as one drive module needs to extend and preload onto the pipe wall to support platform 10, while the other drive module retracts to pass through the XN joint. The retraction process remains the same regardless of the number of drive modules included in different configurations of platform 10. Each drive module retracts and passes through the XN joint while being supported by the other drive modules. This retraction and extension of the arm and contact surface can be performed on each drive module until the end of platform 10 clears narrow downhole environments such as the XN joint retraction. This is to facilitate transitions between downhole environments of different lateral widths, such as... Figure 2As shown, the mobile platform 10, while traversing downhole environments such as pipes or XN joints, optionally utilizes a continuous drive mechanism under the control of a program executed in its associated processor, following any commands that may have been received from the user. When moving from one downhole dimension to another, the platform 10 detects the transition using one or more sensors from appropriately configured modules such as sensor modules 12, 30, and sends control signals to computing modules 16, 28 to retract or extend the contact surfaces on the arms of the corresponding drive modules, depending on the type of transition. In one example, the contact surfaces retract to pass through the XN joint and extend to preload onto the bare well or erosion environment.

[0042] refer to Figure 1 The computing modules 16 and 28 are located at an intermediate position between the various modules 12-32 of platform 10. Computing modules 16 and 28 include a housing for holding the motor controller and core processing unit (“processor”, as previously described), and memory for storing code, settings, and data collected during downhole operations, all connected to the motor controller. This is used to control nearby drive modules associated with the respective computing modules. The housing may be made of aluminum. Computing modules 16 and 28 may also include independent heat sinks thermally connected to the aluminum housing for heat dissipation during operation of platform 10. In an alternative embodiment, the heat sink pattern is milled into the aluminum base of computing modules 16 and 28 to ensure good thermal contact and heat dissipation during operation of platform 10. In one embodiment, computing modules 16 and 28 have no external sensors or effectors and are therefore dedicated to communicating with and controlling other modules in platform 10. In an alternative embodiment, computing modules 16 and 28 may include external sensors or effectors for detecting and executing actions at intermediate positions relative to the total length of platform 10 in the downhole environment.

[0043] Each end of computing modules 16 and 28 is connected to an adjacent drive module. The motor controller can be directly connected to the drive motor of the adjacent drive module. Therefore, signals from the motor controller are transmitted to the drive motor to control the power application from the drive module's battery to the drive motor. In an alternative embodiment, the motor controller and drive motor can be connected to their respective wireless communication units. Using the wireless communication units, the motor controller can wirelessly control the drive motor of the drive module. WiFi or Bluetooth can be used. TM Wireless control can be achieved using other known communication protocols. Using a motor controller and a core processing unit, computing modules 16 and 28 can perform local closed-loop motion and preload control via logic implemented by code executed in the processor. Combining data collected from sensor modules 12 and 32, platform 10 responds to commands received from a remote user to perform autonomous position estimation, downhole feature detection, and downhole feature navigation, or in some embodiments, semi-autonomous downhole feature navigation.

[0044] Using data collected from the preceding sensor module 12, code executing in the processor of each computing module 16, 28 determines features in the upcoming section of the downhole environment. This code determines the width of the upcoming section of the downhole environment based on these features. Each computing module 16, 28 uses first predetermined logic implemented by the code executing in the processor. Using this first predetermined logic, the computing modules 16, 28 generate a first signal transmitted to the drive module to extend or retract the arm and contact surface of the corresponding drive module, thereby preloading the contact surface onto the wall of the downhole environment to assemble the mobile platform 10 into the upcoming section. Each computing module 16, 28 uses second predetermined logic implemented by the code executing in the processor. Using this second predetermined logic, the computing modules 16, 28 generate a second signal transmitted to the drive module to rotate the contact surface. The contact surface is preloaded onto the wall of the downhole environment. Therefore, the mobile platform 10 advances into the upcoming section of the downhole environment.

[0045] refer to Figure 5-8 Sensor modules 12 and 32 include a housing 48 with an opening 50, in which at least one sensor 52 is disposed. In one embodiment, sensor modules 12 and 32 have a plurality of spaced-apart sensors 52 connected to a processor. The processor implements code configured to interact with the sensors 52 to collect distance data. The processor has a wireless communication device for wirelessly transmitting distance data from the sensors 52 to corresponding computing modules 16 and 28. Furthermore, the wireless communication device receives control signals from the corresponding computing modules 16 and 28 for controlling components within the respective sensor modules 12 and 32. The wireless communication device supports the use of WiFi and Bluetooth. TM Antennas that transmit and receive signals using other known communication protocols.

[0046] Each sensor 52 operates as a range sensor, and in Figure 7 Signals are emitted through aperture 50 within the range 54 shown. The emitted signals are transmitted in a direction that is 0° forward and acute-angled relative to the longitudinal axis of platform 10. The emitted signals can be light, radio waves, microwaves, or ultrasound, which are reflected by features in the downhole environment ahead. In one particular embodiment, at least one sensor comprises a combination of an ultrasonic transmitter and a detector. In another embodiment, the transmitter and detector are discrete components and are both configured to emit and receive ultrasonic signals, respectively. The reflected signals (e.g., ultrasonic signals) are detected by sensor 52 and converted in a conventional manner into distance data transmitted to the corresponding computing modules 16, 28. Each sensor 52 allows platform 10 to estimate the width of the downhole environment ahead of platform 10, such as wall 55, which improves the fidelity of the preload system and allows autonomous passage through downhole environments of varying widths, such as XN joints.

[0047] refer to Figure 5-6 The rear sensor module 32, located at the rear of platform 10, may further include at least one sensor 52 that allows platform 10 to detect rearward downhole features as platform 10 moves backward, for example, during the process of a drilling rig retrieving platform 10 from a downhole environment. Using data collected from the rear sensor module 30, code executing in the processor of each computing module 16, 28 determines features in the upcoming rear portion of the downhole environment behind the moving platform 10. The code determines the width of the upcoming rear portion of the downhole environment based on these features. Each computing module 16, 28 uses first predetermined logic implemented by code executing in the processor. By using the first predetermined logic, computing modules 16, 28 generate first signals transmitted to drive modules to extend or retract the arms and contacts of the respective drive modules, thereby preloading the contacts onto the walls of the downhole environment to assemble the moving platform 10 into the upcoming rear portion. Each computing module 16, 28 uses second predetermined logic implemented by code executing in the processor. By using the second predetermined logic, computing modules 16, 28 generate second signals transmitted to drive modules to rotate the contacts. The contact surface is preloaded onto the wall of the downhole environment. Therefore, the mobile platform 10 can retract into the upcoming rear of the downhole environment. For example, the retraction of the mobile platform 10 can be performed when it is removed from the downhole environment.

[0048] In one embodiment, such as Figure 5-6 As shown, the rear sensor module 32 does not need to include as many sensors 52 as the front sensor module 12. In the illustrated embodiment, a fishneck cable interface 53 extends through the tether 34 and provides an interface for deploying and retrieving drilling equipment when the platform 10 is deployed into or withdrawn from the downhole well or pipeline. Interface 53 provides in-situ engagement with and disengagement from the fishneck interface with the drilling equipment. Furthermore, the rear sensor module 32 includes a wireless communication device for uplinking data from an external console to the platform 10. Alternatively, at least one of the computing modules 16, 28 includes a wireless communication device for uplinking data from an external console to the platform 10.

[0049] refer to Figure 8-9The front end 56 of the front sensor module 12 includes a hinged arm 58. In the illustrated embodiment, the hinged arm 58 is rotatably mounted to the front end 56. For example, the joint for arm rotation may include a ball-and-socket member 60. In this configuration, the ball-and-socket member 60 has a generally spherical end 62 of the arm 58 located in a socket opening of the member 60. Regardless of the specific mounting of the hinged arm 58, it is connected to an actuator 59 for bending the hinged arm 58. In one or more embodiments, a processor associated with the front sensor module 12 executes code that causes the arm to hinge in a direction away from the main borehole and toward a branch or steering portion of the downhole embodiment. When the mobile platform is in autonomous operating mode, signals from the sensor 52 are processed by an algorithm to select the direction of travel for the mobile platform. The selected direction may take into account the detected characteristics of the path within the downhole environment, including the main borehole or lateral paths encountered during transport of the mobile platform 10. Among other things, these characteristics may include the size of the detected main borehole and lateral passages encountered within the downhole environment, any gases and their respective concentrations, and other samples of the borehole wall, moisture, humidity, temperature, or other parameters. Thus, as a result of onboard analysis of the detected signals and information, the mobile platform 10 can continue traveling along the main borehole, or alternatively, hinge the arm 58 toward a specific lateral direction selected by an algorithm. Therefore, the sensor module 12 can manipulate the mobile platform 10 in the selected direction. The actuator 59 includes an internal motor for bending the arm 58 at angles within a maximum angle range 64. For example, the motor may be part of a solenoid or worm gear, which hinges the arm away from the longitudinal axis of the mobile platform 10.

[0050] Figures 8A-8B An alternative embodiment of actuator 59 is shown. (e.g.) Figure 8A As shown, in one embodiment, actuator 159 may be a one-degree-of-freedom (1-DOF) tendon-actuated joint using push / pull cables and pulleys. In another embodiment, actuator 159 utilizes a hinged gear mechanism. (See reference...) Figure 8A The actuator 159 includes an arm 58, which can be relative to Figure 8 The base 161 in the ball joint 60 is bent at least by an angle q. A first internal motor 163, acting as a first joint, rotates to bend the arm 58 to a selected angle q. A second internal motor 165 selectively pulls the tendon 167 to control and stabilize the bending of the arm 58 about the axis of the first internal motor 163.

[0051] like Figure 8BAs shown, in another embodiment, actuator 259 may have multiple internal motors as joints to provide at least two degrees of freedom (2-DOF) tendon-actuated joints. A first motor 263, serving as the first joint, is articulated at an angle q3 relative to the base 261 to the arm 58. Another motor, serving as the second joint, may be located at the end 265 of the arm 58, articulated at an angle q4 relative to the arm 58. Actuator 259 has a rotational axis about a main axis, followed by a second degree of freedom perpendicular to the main rotational axis, actuating the steering head. Tendons 267, 269 control and stabilize the bending of the arm 58 about the axis of a joint, such as joint 263.

[0052] refer to Figures 8A-8B The internal motors 163, 165, and 263 of actuators 159 and 259 are controlled by wireless signals from nearby computing modules, such as computing module 16. (Return to Reference) Figure 8 This angular bending of the articulated arm 58 causes the tip of the arm 58 to move laterally in the selected lateral direction together with the sensor 52. (Reference) Figure 9 Lateral movement of arm 58 allows housing 48, carrying sensor 52, to navigate through gap 66 in the downhole environment, enabling mobile platform 10 to enter one path 68 instead of another path 70. Therefore, the front sensor module 12 acts as a navigation module for mobile platform 10, allowing the drive module to move mobile platform 10 in a selected direction in the upcoming portion of the downhole environment.

[0053] This disclosure also includes a system having at least a mobile platform 10 and control equipment such as an external console. The platform 10 communicates with the control equipment, for example, via wireless communication from at least one computing module 16, 28. The control equipment may include a display, wireless antenna, control panel, and handheld controller mounted in a housing. The housing may be adapted as a carrying case for transporting the control equipment to the location where the platform 10 is to be operated. In an alternative embodiment, the system does not include control equipment and does not include a tether between the mobile platform 10 and the drilling rig on the earth's surface. Therefore, the mobile platform 10 can be fully autonomous within the downhole environment.

[0054] like Figure 10As shown, this disclosure also includes a method 200 for operating a mobile platform 10. Method 200 includes the step of interconnecting multiple modules in step 210 to form the mobile platform 10, including sensor modules, drive modules, and computing modules. The interconnection step may include physically connecting discrete modules with a rigid coupling or joint that allows relative angles to be achieved from one module to the next during traversal of a downhole environment. The physical connection of the modules may be a removable coupling. A removable coupling can be established using removable fasteners. Such fasteners may be screws. Screws may removably engage screw holes on opposing surfaces of physically adjacent modules to secure the modules together. Alternatively, a removable coupling may be established using complementary surfaces on opposing portions of adjacent modules. Complementary surfaces may use a friction fit to secure adjacent modules together.

[0055] The method includes deploying the modules thus connected as a unified mobile platform 10 into the downhole environment in step 220. Deployment can be performed by an operator of a drilling rig on the Earth's surface. The drilling rig may include a tether 34 attached to the rear sensor module 32 of the mobile platform 10. The operator can manually guide the platform 10 downhole. The downhole may be a well. The operator can instruct the drilling rig mechanism to lower the platform 10 into the downhole.

[0056] Once the mobile platform 10 is positioned in the downhole environment, the method includes detecting features of the downhole environment using the front sensor module 12 in step 230. The front sensor module 12 sends a command from the processor executing the code to the sensor 52. In response to the command, the sensor 52 emits a sensor signal from the front sensor module 12. The sensor signal may be ultrasonic. Alternatively, the sensor signal may be radio waves. In another alternative embodiment, the sensor signal may be microwaves. The sensor signal is reflected by features of the downhole environment. The reflection of the sensor signal is then detected by the sensor 52. In response to the detected reflection, the sensor 52 generates a feature detection signal. The processor of the front sensor module 12 responds to the feature detection signal by sending the feature detection signal to the computing module 16.

[0057] The method then continues in step 240 to determine the width of the upcoming portion of the downhole environment. The width determination is performed by a processor executing code in computation module 16. In response to a feature detection signal, the processor uses code to execute a predetermined algorithm to determine the width of the upcoming portion. The predetermined algorithm maps the feature detection signal to a given sensor 52 to generate a mapping of the upcoming portion with that width.

[0058] Then, in step 250, the method performs the step of extending or retracting the auger contact from the drive module to assemble the mobile platform 10 into the upcoming portion of the downhole environment. As described above, the auger contact 44 on the arm 46 is selectively extended or retracted relative to the longitudinal axis of the mobile platform 10. Using a determined width and the map generated in step 240, the calculation module 16 selects which auger contact 44 will be extended or retracted. The selection of the auger contact 44 is performed by a processor executing the code in the calculation module 16. The processor generates an auger contact extension command. The auger contact extension command is transmitted from the calculation module 16 to one or more drive modules. In response to the auger contact extension command, the given drive module extends or retracts the auger contact 44. Each of these steps can be implemented using the modules described above.

[0059] In step 260, the method continues to advance the mobile platform 10 into the upcoming portion of the downhole environment. As described above, the traction contact 44 on the arm 46 is selectively preloaded onto the wall of the downhole environment. The traction contact 44 is also selectively driven to move forward or backward against the wall. The selective driving of the traction contact 44 is executed by a processor executing the code of the computing module 16. The processor generates traction contact drive commands. The traction contact drive commands are transmitted from the computing module 16 to one or more drive modules. In response to the traction contact drive commands, the given drive module drives the traction contact 44. The driven traction contact 44 moves the associated drive module along the wall of the downhole environment. As the associated drive module moves against the wall, the entire mobile platform 10 moves against the wall. Thus, the platform 10 advances into the upcoming portion of the downhole environment.

[0060] Parts of the methods described herein can be executed by software or firmware in a machine-readable form on a tangible (e.g., non-transitory) storage medium. For example, the software or firmware can be in the form of a computer program comprising computer program code adapted to cause a modular mobile platform to perform the various actions described herein when run on a computer or suitable hardware device, and wherein the computer program can be contained on a computer-readable medium. Examples of tangible storage media include computer storage devices having computer-readable media such as disks, thumb drives, flash memory, etc., and excluding propagation signals. Propagation signals can be present in the tangible storage medium. The software can be adapted to execute on a parallel or serial processor, such that the various actions described herein can be performed in any suitable order or simultaneously.

[0061] It should also be understood that the same or similar numbers in the accompanying drawings represent the same or similar elements in multiple drawings, and not all embodiments or arrangements require reference to all parts or steps described and illustrated in the accompanying drawings.

[0062] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the invention. 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 “comprising,” “including,” and / or “having,” and variations thereof, specify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0063] The directional terms used herein are for convention and reference purposes only and should not be construed as limiting. However, it should be recognized that these terms may be used to refer to an operator or user. Therefore, no limitation is implied or inferred. Furthermore, the use of ordinal numbers (e.g., first, second, third) is for distinction rather than counting. For example, the use of “third” does not imply the existence of a corresponding “first” or “second.” Moreover, the wording and terminology used herein are for descriptive purposes and should not be considered limiting. The use of “including,” “comprising,” “having,” “containing,” and variations thereof in this document means including the items listed thereafter and their equivalents, as well as additional items.

[0064] While this disclosure has described several exemplary embodiments, those skilled in the art will understand that various changes can be made without departing from the spirit and scope of the invention, and equivalents can replace its elements. Furthermore, those skilled in the art will understand that many modifications can be made to the embodiments of this disclosure to adapt particular tools, situations, or materials to the embodiments of this disclosure without departing from the basic scope of this disclosure. Therefore, the invention is not limited to the specific embodiments disclosed, nor to the best mode of carrying out the invention, but rather the invention will include all embodiments falling within the scope of the appended claims.

[0065] 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 shown and described, and without departing from the true spirit and scope of the invention contained in this disclosure, which is defined by a set of claims and structures, functions or steps equivalent to those claims.

Claims

1. A mobile platform (10) having a longitudinal axis and capable of traveling in a downhole environment (36), comprising: A plurality of interconnected modules (12-32), including a navigation module (12) located at the front end of the modules (12-32), wherein the navigation module (12) has a first processor executing first code therein, the first processor being configured to detect features of the downhole environment (36), generate data signals corresponding to the detected features, and direct the plurality of interconnected modules (12-32), including the mobile platform (10), to the features within the downhole environment (36), the navigation module (12) comprising: The front end (56) has a socket (60); The articulated arm (58) has a spherical end (62) that is rotatably mounted in a socket (60); Sensor (52), which is disposed at the front end of the articulated arm (58), is configured to detect features of the downhole environment (36); and An actuator (59) is connected to bend the articulated arm (58) in a selected lateral direction; and Its characteristic is that it further includes: The first drive module (14) of the multiple interconnected modules (12-32) has a first drive module longitudinal axis that coincides with the longitudinal axis of the mobile platform and three first traction contact surfaces (44) spaced apart from each other by 120 degrees around the first drive module longitudinal axis. The three first traction contact surfaces (44) can extend radially outward from the first drive module longitudinal axis and can retract radially inward toward the first drive module longitudinal axis. A second drive module (18) among a plurality of interconnected modules (12-32) has a second drive module longitudinal axis that coincides with the longitudinal axis of the moving platform and three second traction contact surfaces (44) spaced apart from each other by 120 degrees about the longitudinal axis of the second drive module. The three second traction contact surfaces (44) can extend radially outward from the longitudinal axis of the second drive module and can retract radially inward toward the longitudinal axis of the second drive module. The three second traction contact surfaces (44) are rotated by a non-zero angle about the longitudinal axis of the moving platform to be spaced apart by a non-zero angle relative to the three first traction contact surfaces (44). A computing module (16) among multiple interconnected modules (12-32), the computing module (16) having a computing housing disposed along the longitudinal axis of the moving platform between the first drive module (14) and the second drive module (18), the computing module (16) having a second processor within the computing housing and executing second code therein, the second code being configured to determine a first width of an upcoming portion of the downhole environment (36) in response to data signals; and The calculation module (16) is also configured as follows: The first drive module (14) and the second drive module (18) are controlled by a first wireless signal sent to the first drive module (14) and the second drive module (18) to extend or retract three first traction contact surfaces (44) spaced 120 degrees apart from each other around the longitudinal axis of the first drive module, and three second traction contact surfaces (44) spaced 120 degrees apart from each other around the longitudinal axis of the second drive module, the three first traction contact surfaces (44) being radially outward or radially inward from the longitudinal axis of the first drive module, and the three second traction contact surfaces (44) being radially outward or radially inward from the longitudinal axis of the second drive module, so that each of the first drive module (14) and the second drive module (18) is configured to have a second width less than the first width, so as to assemble the moving platform (10) into the upcoming section in the selected lateral direction, and The first drive module (14) and the second drive module (18) are controlled by a second wireless signal sent to the first drive module (14) and the second drive module (18) to drive three first traction contact surfaces (44) and three second traction contact surfaces (44) spaced 120 degrees apart from each other around the longitudinal axis to move the mobile platform (10) in the upcoming section in a selected lateral direction.

2. The mobile platform (10) according to claim 1, wherein, The sensor (52) emits a detection signal in the forward direction to detect the feature.

3. The mobile platform (10) according to claim 2, wherein, The detection signal includes ultrasound.

4. The mobile platform (10) according to any of the preceding claims, wherein, The computing module (16) is also configured to: The actuator (59) is controlled to bend the articulated arm (58) in a selected lateral direction to guide the articulated arm (58) toward the upcoming section of the downhole environment (36).

5. The mobile platform (10) according to claim 4, wherein, The sensor (52) emits a detection signal in the lateral direction to detect the feature.

6. The mobile platform (10) according to claim 5, wherein, The detection signal includes ultrasound.

7. The mobile platform (10) according to any of the preceding claims, wherein, The navigation module (12), the computing module (16), the first drive module (14), and the second drive module (18) are linearly interconnected.

8. The mobile platform (10) according to claim 7, wherein, The navigation module (12), computing module (16), first drive module (14), and second drive module (18) are removably interconnected.

9. The mobile platform (10) according to any of the preceding claims, wherein, Each of the navigation module (12), the computing module (16), the first drive module (14), and the second drive module (18) has a housing that is a basic cylindrical shape with the longitudinal axis of the respective module.

10. The mobile platform (10) according to claim 9, wherein, The navigation module (12), the computing module (16), the first drive module (14), and the second drive module (18) are interconnected with the longitudinal axes of the corresponding modules, which are substantially aligned to form the mobile platform (10) and define a basic cylindrical shape along the longitudinal axis of the mobile platform.

11. The mobile platform (10) according to claim 1, wherein, The non-zero angle is 60 degrees.

12. A method of using a mobile platform (10), comprising: Multiple modules (12-32) are interconnected to include a mobile platform (10), said multiple modules (12-32) including a computing module (16), a first driving module (14), a second driving module (18), and a navigation module (12) at the front end of the modules (12-32). The navigation module (12) has a first processor executing first code therein, the first processor being configured to detect features of the downhole environment (36), generate data signals corresponding to the detected features, and direct a plurality of interconnected modules (12-32) including the mobile platform (10) toward the features within the downhole environment (36). The navigation module (12) includes: a front end (56) having a socket (60); a hinged arm (58) having a spherical end (62) rotatably mounted in the socket (60); a sensor (52) disposed at the front end of the hinged arm (58) and configured to detect the features; and an actuator (59) connected to bend the hinged arm (58) in a selected lateral direction. Its characteristic is that it further includes: The first drive module (14) has a first drive module longitudinal axis that coincides with the longitudinal axis of the mobile platform and three first traction contact surfaces (44) spaced apart from each other by 120 degrees around the first drive module longitudinal axis. The three first traction contact surfaces (44) can extend radially outward from the first drive module longitudinal axis and can retract radially inward toward the first drive module longitudinal axis. The second drive module (18) has a second drive module longitudinal axis that coincides with the longitudinal axis of the moving platform and three second traction contact surfaces (44) spaced apart from each other by 120 degrees around the second drive module longitudinal axis. The three second traction contact surfaces (44) can extend radially outward from the second drive module longitudinal axis and can retract radially inward toward the second drive module longitudinal axis. The three second traction contact surfaces (44) rotate about the longitudinal axis of the moving platform by a non-zero angle to be spaced apart by a non-zero angle relative to the three first traction contact surfaces (44). The computing module (16) has a computing housing disposed along the longitudinal axis of the moving platform between the first drive module (14) and the second drive module (18). The computing module (16) has a second processor within the computing housing and executes second code therein, the second code being configured to determine a first width of an upcoming portion of the downhole environment (36) in response to data signals; and The calculation module (16) is also configured as follows: The first drive module (14) and the second drive module (18) are controlled by a first wireless signal sent to the first drive module (14) and the second drive module (18) to extend or retract three first traction contact surfaces (44) spaced 120 degrees apart from each other around the longitudinal axis of the first drive module, and three second traction contact surfaces (44) spaced 120 degrees apart from each other around the longitudinal axis of the second drive module, the three first traction contact surfaces (44) being radially outward or radially inward from the longitudinal axis of the first drive module, and the three second traction contact surfaces (44) being radially outward or radially inward from the longitudinal axis of the second drive module, so that each of the first drive module (14) and the second drive module (18) is configured to have a second width less than the first width, so as to assemble the moving platform (10) into the upcoming section in the selected lateral direction, and The first drive module (14) and the second drive module (18) are controlled by a second wireless signal sent to the first drive module (14) and the second drive module (18) to drive three first traction contact surfaces (44) and three second traction contact surfaces (44) spaced 120 degrees apart from each other around the longitudinal axis to move the mobile platform (10) in the upcoming section in the selected lateral direction. Deploy the mobile platform (10) into the downhole environment (36); Detect the characteristics of the downhole environment (36); Determine the first width of the upcoming portion of the downhole environment (36); The three first traction contact surfaces (44) of the first drive module (14) and the three second traction contact surfaces (44) of the second drive module (18) are moved to assemble the moving platform (10) into the upcoming section; and The mobile platform (10) will be advanced into the upcoming section of the downhole environment (36).

13. The method according to claim 12, wherein, Moving the three first traction contact surfaces (44) and the three second traction contact surfaces (44) includes extending the three first traction contact surfaces (44) or the three second traction contact surfaces (44) from the first drive module (14) or the second drive module (18) respectively, or retracting the three first traction contact surfaces (44) or the three second traction contact surfaces (44) towards the first drive module (14) or the second drive module (18) respectively, before advancing the mobile platform (10) into the upcoming section of the downhole environment (36).

14. The method according to claim 12, wherein, The non-zero angle is 60 degrees.

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