Bidirectional Chopper Frequency Conversion for Downhole Transformer Size Reduction
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Solution Overview
Problem
The existing downhole tools require large transformers due to low frequency power signals, which occupy valuable space and increase transmission losses, necessitating a reduction in transformer size while maintaining power delivery.
Innovation Solution
A bidirectional chopper is used to increase the frequency of the power signal from a standard 50/60 Hz to a range of 400 Hz to 1 kHz, allowing for a smaller transformer size while maintaining power delivery and providing galvanic isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If the frequency of the alternating current (AC) power sent from the surface is increased to reduce transformer size, then the transformer size is reduced, but transmission losses increase and new power sources are required at the surface location
Solution Approach 1:
Instead of increasing the frequency at the surface (which causes transmission losses), the patent inverts the approach by maintaining low frequency transmission and performing frequency conversion at the downhole tool. The bidirectional chopper converts the low frequency AC power received from the surface into high frequency AC power locally, achieving small transformer size without increasing transmission losses.
Solution Approach 2:
The bidirectional chopper acts as an intermediary device that receives low frequency power from the surface, converts it to high frequency power, and supplies it to the transformer. This intermediary conversion process allows the system to benefit from both low frequency transmission (low losses) and high frequency transformation (small size).
2Power
If transformers are connected in parallel to meet increasing power requirements, then power capacity is increased, but device complexity and space requirements increase
Solution Approach 1:
The patent changes the frequency parameter of the power signal to achieve a more compact transformer design. By operating at higher frequency, a single transformer can provide the same power capacity as multiple parallel transformers would provide at lower frequency, thereby reducing both the number of components and overall system complexity.
3Power
If transformers are connected in parallel to meet power requirements, then power capacity is increased, but the space occupied in the downhole tool increases
Solution Approach 1:
By changing the operating frequency parameter to a higher value, the patent enables a single transformer to deliver the same power capacity that would otherwise require multiple parallel transformers. This frequency parameter change directly reduces the volume occupied by power transformation equipment in the constrained downhole environment.
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 reduces transformer size by approximately half, minimizing space requirements and transmission losses while ensuring adequate power supply to downhole tools, enabling more compact and efficient power delivery systems.
Implementation Method 1
chopping the first power signal at the downhole tool to generate a second power signal having a second frequency greater than the first frequency
Data Source
AI summary
A downhole tool and a method for operating the downhole tool are disclosed. A first power signal is supplied to the downhole tool from a power source at a first frequency. A bidirectional chopper at the downhole tool chops the first power signal to generate a second power signal having a second frequency greater than the first frequency. The second power signal is used to operate the downhole tool.