Annular Inductive Core With Diagonal Walls for Downhole Signal Coupling

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Solution Overview

Problem

Reliably transmitting data across downhole tool joints in oil and gas drilling is challenging due to rotational misalignment, inconsistent axial alignment, harsh environmental conditions, and signal degradation, which affects the performance of inductive transmission elements.

Innovation Solution

An annular inductive transmission element with a magnetically conductive, electrically insulating core and a polished mating surface is used, along with a biasing member to ensure consistent impedance and reduced magnetic field dispersion, enhancing signal coupling and robustness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If inductive transmission elements are used at tool joints, then data transmission is enabled across connected tools, but signal loss and dispersion occur due to misalignment and harsh conditions

Engineering Contradiction:

Improvedata transmission reliabilityVSAvoidsignal loss

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent employs curved or spherical contact surfaces on the inductive transmission elements instead of flat surfaces. This curvature allows the elements to maintain consistent contact and alignment despite rotational misalignment and axial inconsistency between tool joints, thereby reducing signal dispersion and loss while maintaining reliable data transmission

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The patent modifies physical parameters of the inductive transmission elements such as contact surface geometry, material properties, and dimensional tolerances to optimize signal coupling. These parameter changes enable the elements to withstand harsh downhole conditions and maintain consistent electrical and magnetic characteristics, reducing signal loss without compromising transmission reliability

Inventive Principle:

Principle #35Parameter changes

2Reliability

If inductive transmission elements are located on the primary shoulder, then connectivity is achieved, but stress on the element increases

Engineering Contradiction:

ImproveconnectivityVSAvoidelement stress resistance

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent relocates the inductive transmission elements from the primary shoulder to the secondary shoulder of the tool joint. This dimensional relocation places the elements in a position with lower mechanical stress while maintaining electrical connectivity through the tool joint assembly, thereby protecting the elements from excessive stress during drilling operations

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Device complexity

If direct electrical contacts are used, then simple construction is achieved, but arcing may occur that ignites flammable substances

Engineering Contradiction:

Improvetransmission element constructionVSAvoidarcing and ignition risk

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces direct electrical contact mechanisms with inductive coupling between magnetically conductive elements. This substitution eliminates the need for direct electrical contact, thereby preventing arcing and the associated risk of igniting flammable drilling fluids or gases, while maintaining relatively simple construction through the use of passive magnetic coupling

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution improves signal coupling and reduces signal loss, providing reliable connectivity and efficient data transmission across the drill string, even in harsh downhole conditions, by minimizing magnetic field leakage and maintaining consistent impedance.

Implementation Method 1

An inductive transmission element functions by converting electrical signals to magnetic fields for transmission across the tool joint

Methodology Applied

Scientific EffectMagnetic field: Magnetic Field

Implementation Method 2

a magnetically conductive, electrically insulating, MCEI, material surrounding the conductor to provide a magnetic path for the magnetic field emanated from the conductor

Methodology Applied

Scientific EffectMagnetic path: Magnetic Field

Implementation Method 3

A corresponding inductive transmission element located on the next downhole tool converts the magnetic field back to an electrical signal where it may be transmitted along the drill string

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS12142419B2Inductive transmission element with diagonal side walls

Publication Date: 2024.11.12 FOX JOE

AI summary

An inductive transmission element comprising a magnetically conductive electrically insulating, MCEI, annular core. The core comprises an outer wall and an inner wall apart from the outer wall. The respective walls are joined by a planar top surface. The inner wall and the outer wall form an annular trough opening adjacent the top surface. The open annular trough comprises opposed diagonal walls that intersect the top surface and a circular region at the distal end of the opposed diagonal walls. The annular trough opening may be wider or narrower than the planar top surface between the diagonal walls and outer surface. The annular core may be disposed within an annular housing comprising a polymeric block. The diagonal walls may intersect the top surface at an angle greater than 93°. The diagonal walls may intersect the circular region at an angle greater than 93°. The top surface may be polished.