Communication composite load-bearing cable

Abstract

The application discloses a communication composite load-bearing cable and relates to the technical field of cables. The communication composite load-bearing cable comprises a cable core, a signal line layer, a load-bearing layer and an outer sheath which are sequentially arranged from inside to outside, and the communication composite load-bearing cable sequentially penetrates through various ultrasonic wave short sections. Control units of the various ultrasonic wave short sections are connected in parallel to the cable. The cable core is led out through a crimping T-shaped joint to branch for high-power high-voltage power supply for the various ultrasonic wave short sections. The signal line layer is uniformly provided with a plurality of pairs of bidirectional communication signal lines. The signal lines are used for bidirectional signal transmission for the various ultrasonic wave short sections. The various ultrasonic wave short sections are clamped and fixed to the outer sheath through detachable clamping blocks or detachable clamping blocks. The load-bearing layer is used for bearing the weight of the load-bearing layer and the various ultrasonic wave short sections. The application meets the load-bearing demand of the cable through the load-bearing layer and supplies power through the cable core. The whole viscosity reduction system is made into an intelligent downhole network integrating sensing, control and execution.

Description

Technical Field

[0001] This invention relates to the technical field of cables, and in particular to a communication composite load-bearing cable. Background Technology

[0002] In downhole distributed ultrasonic atomization devices and methods used for viscosity reduction of crude oil in wellbores, multiple ultrasonic transmitting sections need to be axially deployed within the narrow annulus (typically 15-40 mm) of the tubing-casing connection. Downhole ultrasonic transducers (usually based on piezoelectric ceramics) require high-voltage electrical pulses for excitation to generate strong ultrasonic waves sufficient to penetrate the oil layer or effectively process it. The operating status (start / stop, power, duty cycle) of each ultrasonic transmitting section needs to be independently controlled from the surface, while sensors integrated into some sections need to transmit data back. This requires the deployed cables to simultaneously possess the following functions: transmit high-voltage AC or DC power sufficient to drive multiple ultrasonic transducers; carry multiple independent bidirectional control and data signals; and possess extremely high tensile strength to support their own weight and the weight of multiple sections.

[0003] Existing armored power cables or logging cables have limited functionality, with power transmission and signal communication typically achieved through separate cables: power cables (such as submersible pump cables) only have high-power transmission capabilities and do not contain multiple independent signal transmission channels; logging cables (such as seven-core logging cables), although containing multiple signal wires, have small core cross-sectional areas (typically ≤1mm²). 2 This method cannot transmit the high-power, high-voltage electricity required to drive ultrasonic transducers (typically 100W~500W per short section, total power 3kVA~10kVA). Furthermore, some oilfield solutions use a dual-cable parallel installation of a power cable and an independent signal fiber optic cable. While this solves the functional integration problem, the two cables are prone to tangling and compression within the confined annulus, and the wellhead sealing device requires a dual-hole structure, significantly increasing construction risks and maintenance costs. Therefore, a new cable structure is urgently needed that highly integrates high-power, high-voltage power transmission and multiple independent bidirectional signal communication within a single thin cable. Summary of the Invention

[0004] The purpose of this invention is to provide a communication composite load-bearing cable to solve the problems existing in the prior art, enabling the cable to carry multiple independent bidirectional control and data signals, provide high-power high-voltage electricity, and have sufficient load-bearing capacity and tensile strength.

[0005] To achieve the above objectives, the present invention provides the following solution: This invention provides a communication composite load-bearing cable, comprising, from the inside out, a cable core, a signal line layer, a load-bearing layer, and an outer sheath. The communication composite load-bearing cable sequentially passes through each ultrasonic segment. The control unit of each ultrasonic segment is connected in parallel to the communication composite load-bearing cable. The cable core is led out through crimped T-type connectors to supply high-power, high-voltage electricity to each ultrasonic segment. The signal line layer has several pairs of bidirectional communication signal lines evenly distributed, which are used for bidirectional signal transmission to each ultrasonic segment. Each ultrasonic segment is clamped and fixed to the outer sheath by detachable clamps or detachable clips. The load-bearing layer supports its own weight and the weight of each ultrasonic segment.

[0006] Preferably, the cable core includes a center conductor and an electrical insulation layer, the electrical insulation layer covering the outside of the center conductor, and the cross-sectional area of ​​the center conductor is ≥10mm². 2 .

[0007] Preferably, the center conductor comprises multi-strand copper or copper alloy stranded wire, and the power transmission power of the center conductor is at least 3kVA and the power is at least 100W; the electrical insulation layer is an engineering plastic, and the engineering plastic can withstand a temperature of ≥250℃ for at least 1 year.

[0008] Preferably, the signal line layer includes the signal line and an inner sheath. The signal line is spirally wound around the outside of the cable core with a uniform pitch. The inner sheath is an insulating material and is extruded and wrapped around the outer layer of the signal line and between adjacent signal lines.

[0009] Preferably, the thickness of the inner sheath is not less than the diameter of the signal line, and the inner sheath is made of polytetrafluoroethylene propylene or perfluoroalkoxy resin.

[0010] Preferably, the signal line includes a conductive core, an insulating sleeve, and a shielding layer. The insulating sleeve is extruded over the conductive core to form an insulated core wire. Each signal line includes two twisted insulated core wires, which together form a twisted pair signal line. The shielding layer is wrapped around the insulated core wires. The conductive core is formed by winding multi-strand stranded conductors, and the cross-sectional area of ​​the conductive core is 0.2 mm². 2 ~0.5mm 2 The conductive core is made of pure copper or copper alloy; the two insulated core wires are twisted together with a pitch of 20mm to 40mm; the shielding layer is a woven metal mesh with a coverage of ≥85%; the insulating sleeve is made of fluoroplastic that can withstand 200℃ and has a thickness of 0.1mm to 0.3mm.

[0011] Preferably, at least one ultrasonic stub is connected in parallel on each pair of signal lines, and at least one pair of signal lines is provided.

[0012] Preferably, the load-bearing layer includes a load-bearing filling layer and an armor layer arranged sequentially from the inside to the outside. The load-bearing filling layer is wrapped around the outside of the signal line layer, and the material of the load-bearing filling layer is aramid fiber or ultra-high molecular weight polyethylene fiber.

[0013] Preferably, the armor layer comprises two metal wire braided layers, wherein the metal wire braided layers are metal wires woven or spirally wound around the outside of the load-bearing filling layer, and the braiding angle of the metal wires is 45°~55° or the winding direction is opposite, and the winding pitch of the metal wires is 8~12 times the outer diameter of the armor layer; the compressive strength of the armor layer is ≥100MPa.

[0014] Preferably, the outer sheath is a polymer sheath, which is extruded and coated on the outside of the load-bearing layer; the thickness of the outer sheath is 0.5mm~1.5mm, and it can withstand a pressure ≥100MPa; the outer diameter of the communication composite load-bearing cable does not exceed 20mm.

[0015] The present invention achieves the following technical effects compared to the prior art: This invention meets the load-bearing requirements of the cable through a load-bearing layer and supplies power through the cable core. By evenly distributing several pairs of bidirectional communication signal lines in the signal line layer, multiple signals are transmitted bidirectionally to each ultrasonic sub-section, enabling independent addressing and control of each individual ultrasonic sub-section. This allows for differentiated viscosity reduction based on the crude oil viscosity at different well depths, significantly improving energy efficiency. Each sub-section can also independently transmit data such as temperature and pressure, providing the surface with detailed diagnostic information along the wellbore. Furthermore, the operating parameters of each sub-section can be remotely adjusted to optimize its lifespan, thus creating an intelligent downhole network integrating sensing, control, and execution. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the structure of the communication composite load-bearing cable in an embodiment of the present invention; Figure 2 This is a schematic diagram of the cross-sectional structure of the communication composite load-bearing cable in an embodiment of the present invention; Figure 3This is a schematic diagram of the cross-sectional structure of the signal line in an embodiment of the present invention; In the diagram: 1-Center conductor, 2-Electrical insulation layer, 3-Signal line, 31-Conductive core, 32-Insulating sleeve, 33-Shielding layer, 4-Inner sheath, 5-Bearing filler layer, 6-Armor layer, 7-Outer sheath. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] It should be noted that in the description of this invention, the terms "upper," "lower," "left," "right," "inner," "outer," "front," "rear," "clockwise," and "counterclockwise," etc., indicating directional or positional relationships, are based on the directional or positional relationships shown in the accompanying drawings. These are merely for ease of description and do not indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation; therefore, they should not be construed as limitations on this invention. Furthermore, the terms "first," "second," "third," and "fourth" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first," "second," "third," and "fourth" may explicitly or implicitly include one or more of the stated features. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0020] Furthermore, it should be noted that, in the description of this invention, unless otherwise explicitly specified and limited, the terms "set," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0021] The purpose of this invention is to provide a communication composite load-bearing cable to solve the problems existing in the prior art, enabling the cable to carry multiple independent bidirectional control and data signals, provide high-power high-voltage electricity, and have sufficient load-bearing capacity and tensile strength.

[0022] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0023] Example 1 like Figures 1 to 3 As shown, this embodiment provides a communication composite load-bearing cable, including a cable core, a signal line layer, a load-bearing layer, and an outer sheath 7 arranged sequentially from the inside out. The communication composite load-bearing cable passes through each ultrasonic segment in sequence. The control units of each ultrasonic segment are connected in parallel to the communication composite load-bearing cable. The cable core is led out through a crimped T-type connector to provide high-power high-voltage power to each ultrasonic segment. The signal line layer is evenly distributed with several pairs of bidirectional communication signal lines 3 (one for transmitting signals and one for receiving signals). The signal lines 3 are used for bidirectional signal transmission to each ultrasonic segment. Each ultrasonic segment is clamped and fixed to the outer sheath 7 by a detachable clamp or a detachable clip. The load-bearing layer is used to support its own weight and the weight of each ultrasonic segment. This invention meets the load-bearing requirements of the cable through a load-bearing layer and provides power through the cable core. By evenly distributing several pairs of bidirectional communication signal lines 3 in the signal line layer, multiple signals can be transmitted bidirectionally to each ultrasonic sub-section, enabling independent addressing and control of each ultrasonic sub-section. This allows for differentiated viscosity reduction based on the crude oil viscosity at different well depths, significantly improving energy efficiency. Inside each ultrasonic sub-section, the central power conductor of the cable core branches out through a crimped T-type connector to power the sub-section's power module. Each ultrasonic subsection is fixed to the outer sheath 7 by detachable clamps or slips. The cable bearing structure dominated by the load-bearing layer bears the weight of the subsection and prevents axial slippage. A designated pair of signal lines 3 in the signal line layer are connected in parallel to the control circuit board of the corresponding ultrasonic subsections. Each subsection can also independently transmit data such as temperature and pressure of each ultrasonic subsection, providing the surface with detailed diagnostic information along the wellbore. The working parameters of a single subsection can be remotely adjusted to optimize its lifespan, thereby making the entire viscosity reduction system an intelligent downhole network integrating sensing, control and execution.

[0024] As an optional embodiment, the cable core includes a center conductor 1 and an electrical insulation layer 2, the electrical insulation layer 2 covering the outside of the center conductor 1, and the cross-sectional area of ​​the center conductor 1 is ≥10mm². 2 This facilitates the transmission of the high-power, high-voltage electricity required to drive the ultrasonic transducer.

[0025] As an optional solution, in this embodiment, the center conductor 1 includes multiple strands of copper or copper alloy stranded wire. The power transmission capacity of the center conductor 1 is at least 3kVA and the power is at least 100W. The center conductor 1 is located at the core of the cable and is made of multiple strands of highly conductive copper alloy wire (such as 7 strands or 19 strands) using a regular stranding process. The stranding pitch is 10 to 14 times the stranding outer diameter to ensure conductivity and flexibility. The cross-sectional area of ​​the center conductor 1 is determined according to the transmission power and well depth and is used to transmit the main power.

[0026] The electrical insulation layer 2 is made of engineering plastic, which can withstand temperatures of ≥250℃ for at least one year. High-temperature resistant engineering plastics can be used, preferably polyetheretherketone (PEEK) or modified polytetrafluoroethylene (PTFE), which has a long-term temperature resistance of ≥250℃ and high dielectric strength, ensuring the insulation reliability of high-voltage power transmission. In this embodiment, a high-temperature extruder is used to melt-extrude polyetheretherketone (PEEK) at 380~420℃, uniformly coating the outer layer of the central conductor 1. The layer is then sized and formed using a cooling water bath, requiring an online detection eccentricity of ≤5%.

[0027] As an alternative, in this embodiment, the signal line layer includes a signal line 3 and an inner sheath 4. The signal line 3 is spirally wound around the outside of the cable core with a uniform pitch, and the inner sheath 4 is an insulating material that is extruded and wrapped around the outer layer of the signal line 3 and between adjacent signal lines 3.

[0028] As an optional solution, in this embodiment, the thickness of the inner sheath 4 (i.e., the radial distance between the outer surface of the signal line layer and the outer surface of the inner sheath 4) is not less than the diameter of the signal line 3, and preferably 1.2 to 1.5 times the diameter of the signal line 3. For example, when the diameter of the signal line 3 is 2.0 mm, the thickness of the inner sheath 4 is preferably 2.4 mm to 3.0 mm, with the signal line 3 closer to the outside of the cable core. This design ensures that the inner sheath 4 completely wraps the signal line layer and fills the gaps between the signal lines 3, providing a smooth cylindrical base for the subsequent covering of the load-bearing layer and armor layer 6, and avoiding stress concentration caused by the protrusion of the signal line 3 contour. The inner sheath 4 is made of perfluoroethylene propylene or perfluoroalkoxy resin.

[0029] As an alternative, such as Figure 3 As shown, in this embodiment, the signal line 3 includes a conductive core 31, an insulating sleeve 32, and a shielding layer 33. The insulating sleeve 32 is extruded over the conductive core 31, together forming an insulated core wire. Each signal line 3 includes two twisted insulated core wires, which together form a pair of twisted signal lines 3. The insulated core wires are wrapped with a shielding layer 33. The conductive core 31 is formed by winding multiple strands of conductor, and the cross-sectional area of ​​the conductive core 31 is 0.2 mm². 2 ~0.5mm 2 The conductive core 31 is made of pure copper or copper alloy; the two insulated core wires are twisted together with a pitch of 20mm~40mm; the shielding layer 33 is a woven metal mesh with a coverage of ≥85%; the insulating sleeve 32 is made of fluoroplastic that can withstand 200℃ and has a thickness of 0.1mm~0.3mm. In this embodiment, each signal line 3 consists of two insulated core wires twisted together to form a pair of twisted signal lines, and each conductive core 31 is a conductor made of multiple strands of copper alloy wires twisted together (cross-sectional area 0.2~0.5mm²). 2The signal line 32 consists of an extruded (0.1-0.3mm thick) FEP (polyfluoroethylene propylene) insulating sleeve 32. Two insulated core wires are twisted together at a pitch of 20-40mm, and then an overall woven metal wire shielding mesh is formed, with a shielding mesh coverage of ≥85%. This twisted-pair structure is used to achieve differential signal transmission and suppress common-mode interference in the strong electromagnetic field environment downhole. When an external electromagnetic field acts on the twisted-pair wire, the interference current induced on the two wires has equal amplitude and the same phase (common-mode signal). At the receiving end, the differential amplifier only amplifies the useful signal with opposite phase (differential-mode signal), thus significantly suppressing common-mode interference. In the downhole environment, high-power ultrasonic transducers generate strong electromagnetic interference during operation, and the twisted-pair structure is crucial for ensuring reliable transmission of control signals. In this embodiment, the signal line 3 consists of multiple (e.g., 4-8) twisted-pair signal wires spirally wound around the power insulation layer 2 at a uniform pitch, and the shielding layer 33 is a metal mesh. In this embodiment, the FEP insulating sleeve 32 of the signal line 3 has a temperature resistance of ≥200℃, a low dielectric constant (2.0~2.1), and low signal attenuation. It provides overall insulation and shape stability, making it suitable for signal transmission in high-temperature environments downhole. If the environment is particularly harsh, a thin FEP sheath can be extruded on the outside of the shielding layer 33 to form a complete seal.

[0030] As an optional solution, in this embodiment, at least one ultrasonic sub-section is connected in parallel on each pair of signal lines 3, and at least one pair of signal lines 3 is provided. The signal line layer can transmit independent control commands and sensing data. Each signal line 3 or each pair of twisted (differential) signal lines can correspond to one or a group of ultrasonic sub-sections, achieving independence in the physical channel. In this embodiment, a bus-type independent addressing control protocol is adopted, and multiple ultrasonic sub-sections can share a pair of signal lines 3 for communication. For example, if 12 ultrasonic sub-sections need to be controlled, the following two configuration methods can be used: (1) Single-channel scheme: Only one pair of signal lines 3 is used, and all 12 ultrasonic segments are mounted on this channel. Independent control is achieved through address addressing. This scheme has the simplest structure, but the communication rate must meet the polling cycle requirements. (2) Multi-channel scheme: Four pairs of signal lines 3 are used, and each pair of signal lines 3 manages three ultrasonic segments, reducing the load on a single channel, improving the response speed, and ensuring that a failure in one channel does not affect the other channels.

[0031] As an optional solution, in this embodiment, the load-bearing layer includes a load-bearing filling layer 5 and an armor layer 6 arranged sequentially from the inside to the outside. The load-bearing filling layer 5 is wrapped around the outside of the signal line layer. The load-bearing filling layer 5 is made of aramid fiber (such as Kevlar) or ultra-high molecular weight polyethylene fiber. It is filled uniformly and densely with high-strength fibers outside the inner sheath 4, which can provide the main tensile strength of the cable.

[0032] As an optional solution, in this embodiment, the armor layer 6 includes two layers of braided metal wire. The braided metal wire is woven or spirally wound around the outside of the load-bearing filler layer 5, and the braiding angle of the metal wire is 45°~55° or the winding direction is opposite. The winding pitch of the metal wire is 8~12 times the outer diameter of the armor layer 6; the compressive strength of the armor layer 6 is ≥100MPa. In this embodiment, the armor layer 6 uses high-strength, corrosion-resistant metal wire (such as 304 stainless steel wire, titanium alloy wire, or nickel-based corrosion-resistant alloy (Incoloy 825)) woven or spirally wound in opposite directions around the outside of the load-bearing filler layer 5 to provide mechanical protection against compression and wear, and to serve as the protective grounding for the entire system. When the metal wire is spirally wound, the inner and outer metal wires are spirally wound in opposite directions (one layer is left-handed and the other layer is right-handed). The winding pitch is 8 to 12 times the outer diameter of the armor layer 6. The diameter of the metal wire is selected according to the well depth and annular space gap (e.g., 0.8 to 1.5 mm). The number of inner and outer steel wires is calculated according to the circumference to ensure that the steel wire coverage rate is ≥90%. (1) Mechanical protection: The higher the coverage rate, the more uniform the support of the armor layer 6 to the outer sheath 7, and the stronger the resistance to compression, preventing the outer sheath 7 from collapsing locally under high pressure. (2) Shielding effect: The high coverage rate of the metal armor forms a nearly continuous conductive shell, which enhances the electromagnetic shielding effect. (3) Wear resistance: The steel wires are densely arranged, reducing the wear of a single steel wire and extending the service life.

[0033] The specific calculation method for wire coverage is as follows: Coverage of Armor Layer 6 = (Diameter of a single steel wire × Number of steel wires) / (Circumference of Armor Layer 6) × 100% Taking the armor layer 6 with a diameter D=3.8cm, a steel wire diameter d=0.12cm, and an inner layer with 96 steel wires as an example: The perimeter of armor layer 6 = π × D = π × 3.8 ≈ 11.94 cm Coverage rate = (0.12 × 96) / 11.94 × 100% ≈ 96.5% Specifically, in this embodiment, the armor layer 6 adopts a reverse spiral winding method with stainless steel wires. The distribution pattern, number of wires, and spacing of the stainless steel wires are selected based on: The inner steel wires are spirally wound in a right-hand direction around the outer edge of the inner sheath 4+ load-bearing layer. The number of wires is calculated based on the circumference and diameter. Assume the outer diameter D of the inner armor layer... inner =38mm, wire diameter d=1.2mm, Then the number of inner steel wires N inner = π×(D inner -d) / d ≈ 96 roots (rounded down).

[0034] The outer layer of steel wire is spirally wound around the inner layer in a left-handed direction. The number of outer steel wires is calculated in the same way. Outer diameter D outer = D inner + 2d = 40.4mm, N outer ≈102 pieces.

[0035] Wire cross-section spacing: Adjacent wires are in close contact, and the gap is controlled by the wire diameter tolerance (approximately 0.02mm~0.05mm).

[0036] The selection of wire diameter is determined based on the following factors: Well depth / suspended weight: The thicker the wire, the greater the breaking tensile force of the armor layer 6. For wells shallower than 3000m, 0.8~1.0mm is suitable; for wells 5000m~7000m, 1.2mm~1.5mm is preferred; and for wells above 8000m, 1.5mm~2.0mm is preferred.

[0037] Annular clearance: The thicker the steel wire, the larger the cable outer diameter. It is necessary to ensure that the outer diameter of the armor layer 6 + the thickness of the outer sheath 7 ≤ Annular clearance - safety margin (usually ≥ 5mm).

[0038] Bending radius: The thicker the steel wire, the larger the minimum bending radius of the communication composite load-bearing cable.

[0039] Specifically, the minimum bending radius of the composite load-bearing communication cable is related to the diameter of the armored steel wire, the total outer diameter of the cable, and the structure of the armor layer 6. The specific derivation and calculation process based on the empirical formula is as follows: Static bending radius R static (Storage or transportation status): R static ≥ 8 × D cable D cable This is the total outer diameter of the cable.

[0040] Dynamic bending radius R dynamic (Lowering or lifting operation status): R dynamic ≥ 12 × D cable .

[0041] The outer diameter D of the communication composite load-bearing cable cable For example, with a diameter of 16.8mm: the static bending radius is ≥ 135mm, and the dynamic bending radius is ≥ 202mm.

[0042] If the bending radius is too small, the armored steel wire will undergo plastic deformation or breakage, and the outer sheath 7 and inner sheath 4 may delaminate or crack due to excessive stretching or compression. The above coefficients (8 times and 12 times) are derived from industry standards for steel wire armored cables (such as API RP17B) and engineering practice experience. The thicker the steel wire diameter, the larger the minimum bending radius required (the bending radius is directly proportional to the steel wire diameter).

[0043] Design and wellhead equipment compatibility requirements: The dynamic bending radius of the cable must be smaller than the radius of the ground winch drum and the guide wheel at the wellhead; otherwise, permanent bending deformation will occur on the drum. Therefore, when designing the wire diameter and cable outer diameter, it is necessary to calculate whether the bending radius can meet the usage requirements of the existing operating equipment (drum diameter is typically ≥500mm, guide wheel diameter ≥300mm). For this cable (D... cable With a diameter of ≤20mm and a bending radius of ≤240mm, it fully meets the operating conditions of conventional rollers and guide wheels.

[0044] As an optional solution, in this embodiment, the outer sheath 7 is a polymer sheath, which is extruded and covers the outside of the load-bearing layer; the thickness of the outer sheath 7 is 0.5mm~1.5mm, and it can withstand a pressure ≥100MPa. The outer diameter of the communication composite load-bearing cable does not exceed 20mm, preferably 16mm. In this embodiment, a thin-walled, high-temperature resistant, hydrogen sulfide and carbon dioxide corrosion resistant polymer sheath, such as polyetheretherketone (PEEK) or ethylene-tetrafluoroethylene copolymer (ETFE), is extruded on the outermost layer as an additional corrosion protection barrier.

[0045] The layered radial composite structure of this embodiment functionally separates the central power transmission from the peripheral multi-channel signal transmission, while structurally integrating them. The cross-sectional area of ​​the central conductor 1 is not encroached upon by the signal lines 3, ensuring high-power supply. The spirally wound signal lines 3 on the periphery provide flexibility and multiple physical channels. In terms of integration and outer diameter, high-voltage power, multi-channel control, and data signal transmission functions are converged into a single cable, with an outer diameter controllable between 14 and 20 mm to meet the requirements for entry into narrow annulus spaces. In terms of load-bearing and control capabilities, it can support well depths of over 3000 m and supports independent control and data feedback for up to 32 short sections. In terms of reliability, the overall temperature resistance of the cable reaches 250℃, the tensile strength is ≥60kN, and the design life matches the well workover cycle (≥5 years).

[0046] This embodiment features an integrated design that is resistant to temperature, pressure, and corrosion. All materials (PEEK insulation, FEP sheath, aramid fiber, stainless steel / titanium alloy armor) are selected for extreme downhole environments with long-term high temperatures (≥180℃), high pressures (≥60MPa), and H2S / CO2 content, ensuring that insulation does not fail, strength does not decrease, and corrosion does not cause perforation. Each pair of signal lines 3 supports a bus-based independent addressing control protocol (such as RS-485) to achieve independent control of multiple short sections.

[0047] This invention will use a large cross-sectional area (≥10mm) 2The power conductor is placed at the center, and a signal layer composed of multiple pairs of independent twisted shielded signal lines 3 spirally wound around it is arranged concentrically. A load-bearing layer and an armor layer 6 are then applied to the outside, forming a radially functionally layered and axially continuous single-cable structure. This structure ensures that the cross-sectional area of ​​the central power conductor is not encroached upon by the signal lines 3, meeting the high-power power supply needs of multiple points underground; it also provides an independent physical communication channel through the spirally wound signal lines 3, providing a hardware foundation for independent addressing control of multiple ultrasonic short sections; and the load-bearing layer and armor layer 6 meet the cable's load-bearing requirements. Unlike existing parallel power + signal cable schemes, the single-cable composite structure of this invention fundamentally solves the problems of space occupation and entanglement risks in narrow annular spaces.

[0048] Example 2 This embodiment provides a composite power-bearing communication cable. In a well 3200m deep with a 25mm annular gap, 12 ultrasonic short sections need to be installed. The composite armored cable of this invention is selected, and its structure is as follows: center conductor 1 (copper conductor with a cross-sectional area of ​​12mm²). 2 1-Center conductor, 2-Electrical insulation layer (1.5mm wall thickness) → 8 FEP insulated twisted-pair shielded signal wires 3-Spiral winding (2.0mm outer diameter) → FEP inner sheath 4-Aramid fiber filled load-bearing filler layer 5-Inner and outer double-layer 304 stainless steel wire armor layer 6-ETFE outer sheath 7. The total outer diameter of the communication composite load-bearing cable is 16.8mm, and the cable safety factor after installing and connecting ultrasonic short sections is ≥3.5. The lower end (farthest end downhole) of the center conductor 1 is connected to the power module input terminal of the lowest ultrasonic subsection through high-temperature welding or crimping terminals. Then, parallel wires are led out from inside the ultrasonic subsection to supply power to the remaining ultrasonic subsections in sequence. The upper end (wellhead end) of the center conductor 1 is connected to the adjustable high-voltage power output terminal in the surface control cabinet through an explosion-proof junction box to realize the power supply of each ultrasonic subsection.

[0049] The lower end of each pair of signal lines 3 is soldered to the A / B terminals of the RS-485 transceiver chip (such as MAX485) on the control circuit board of the corresponding ultrasonic segment, and sealed and insulated with heat shrink tubing and high-temperature epoxy resin. If a single-channel bus scheme is adopted, the same pair of signal lines 3 is connected in parallel to the transceiver input terminals of each ultrasonic segment (daisy-chain topology). The upper end of each pair of signal lines 3 is led out through the explosion-proof junction box at the wellhead and connected to the industrial-grade serial server or embedded controller in the ground control cabinet, and finally communicates with the host computer (human-machine interface) via Ethernet / USB.

[0050] The armor layer 6 is reliably connected to the wellhead grounding grid at the wellhead end via a grounding ring (grounding resistance ≤ 4Ω), serving as the protective grounding and electromagnetic shielding ground for the entire system. The metal wire shielding layer of the signal line 3 is suspended at the bottom end of the well (to avoid the formation of ground loop currents from multiple grounding points), and is connected to a grounding ring at a single point at the wellhead end.

[0051] The ground control system uses one pair of signal lines 3 to poll and send power adjustment commands containing 12 different address codes via the RS-485 bus protocol. Each ultrasonic sub-section responds precisely, enabling differentiated viscosity reduction operations in different zones. Each ultrasonic transmitting sub-section's circuit module has a pre-set unique digital address code. All ultrasonic sub-sections are connected in parallel to a designated signal bus (which can be networked using a pair of signal lines 3). They receive command frames from the bus in real time, but only when the target address code in the command frame completely matches its own pre-set address will it parse and execute subsequent commands, simultaneously returning a response signal. This allows for reliable independent control of multiple sub-sections sharing a pair of signal lines 3 (or twisted pairs). In this embodiment, the realization of the independent control effect of multiple ultrasonic short sections depends on the following structural features: (1) The signal line layer is provided with multiple pairs of independent twisted differential signal lines, which provide multiple independent physical communication channels and are the hardware foundation (core structure) for realizing independent addressing of multiple short sections; (2) A single cable runs through all ultrasonic short sections, and the signal line 3 is connected to each ultrasonic short section in parallel, thus constructing a shared bus physical topology; (3) The total outer diameter of the communication composite load-bearing cable is limited to 14mm~20mm, which ensures that a single cable can be lowered into the narrow ring air while carrying multiple channel signal layers, which is convenient for operation, avoids multiple cables from tangling and squeezing, and reduces manufacturing costs.

[0052] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "this embodiment," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with the described embodiment or example, which are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0053] Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. Furthermore, those skilled in the art will recognize that, based on the ideas of this invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this invention.

Claims

1. A composite load-bearing communication cable, characterized in that: The device comprises, from the inside out, a cable core, a signal line layer, a load-bearing layer, and an outer sheath. The communication composite load-bearing cable passes through each ultrasonic segment sequentially. The control units of each ultrasonic segment are connected in parallel to the communication composite load-bearing cable. The cable core is led out through crimped T-type connectors to supply high-power, high-voltage electricity to each ultrasonic segment. The signal line layer has several pairs of bidirectional communication signal lines evenly distributed, which are used for bidirectional signal transmission to each ultrasonic segment. Each ultrasonic segment is clamped and fixed to the outer sheath by detachable clamps or detachable clips. The load-bearing layer supports its own weight and the weight of each ultrasonic segment.

2. The communication composite load-bearing cable according to claim 1, characterized in that: The cable core includes a center conductor and an electrical insulation layer, the electrical insulation layer covering the outside of the center conductor, and the cross-sectional area of ​​the center conductor is ≥10mm². 2 .

3. The communication composite load-bearing cable according to claim 2, characterized in that: The center conductor comprises multiple strands of copper or copper alloy stranded wire, and the power transmission power of the center conductor is at least 3kVA and the power is at least 100W; the electrical insulation layer is made of engineering plastic, and the engineering plastic can withstand a temperature of ≥250℃ for at least 1 year.

4. The communication composite load-bearing cable according to claim 1, characterized in that: The signal line layer includes the signal line and an inner sheath. The signal line is spirally wound around the outside of the cable core with a uniform pitch. The inner sheath is an insulating material and is extruded and wrapped around the outer layer of the signal line and between adjacent signal lines.

5. The communication composite load-bearing cable according to claim 4, characterized in that: The thickness of the inner sheath is not less than the diameter of the signal line, and the inner sheath is made of polytetrafluoroethylene propylene or perfluoroalkoxy resin.

6. The communication composite load-bearing cable according to claim 4, characterized in that: The signal line includes a conductive core, an insulating sleeve, and a shielding layer. The insulating sleeve is extruded over the conductive core to form an insulated core wire. Each signal line includes two twisted insulated core wires, which together form a twisted pair signal line. The shielding layer covers the outside of the insulated core wires. The conductive core is made of multi-strand stranded conductors, and the cross-sectional area of ​​the conductive core is 0.2 mm². 2 ~0.5mm 2 The conductive core is made of pure copper or copper alloy; the two insulated core wires are twisted together with a pitch of 20mm to 40mm; the shielding layer is a woven metal mesh with a coverage of ≥85%; the insulating sleeve is made of fluoroplastic that can withstand 200℃ and has a thickness of 0.1mm to 0.3mm.

7. The communication composite load-bearing cable according to claim 1, characterized in that: At least one ultrasonic stub is connected in parallel on each pair of signal lines, and at least one pair of signal lines is provided.

8. The communication composite load-bearing cable according to claim 1, characterized in that: The load-bearing layer includes a load-bearing filling layer and an armor layer arranged sequentially from the inside to the outside. The load-bearing filling layer is wrapped around the outside of the signal line layer. The material of the load-bearing filling layer is aramid fiber or ultra-high molecular weight polyethylene fiber.

9. The communication composite load-bearing cable according to claim 8, characterized in that: The armor layer comprises two metal wire braided layers. The metal wire braided layers are metal wires that are woven or spirally wound around the outside of the load-bearing filling layer. The braiding angle of the metal wires is 45°~55° or the winding direction is opposite. The winding pitch of the metal wires is 8~12 times the outer diameter of the armor layer. The compressive strength of the armor layer is ≥100MPa.

10. The communication composite load-bearing cable according to claim 1, characterized in that: The outer sheath is a polymer sheath, which is extruded and coated on the outside of the load-bearing layer; the thickness of the outer sheath is 0.5mm~1.5mm, and it can withstand a pressure ≥100MPa; the outer diameter of the communication composite load-bearing cable does not exceed 20mm.

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