Borehole Generator Induction Motor Power
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Solution Overview
Problem
Mud generators in downhole environments are prone to stalling, and battery power is limited, necessitating additional reliable power sources for downhole electronics.
Innovation Solution
A downhole generator coupled to the borehole and driven by the motion of a rotary table, which generates electrical current through a rotor-stator mechanism, supplemented by batteries and a mud generator for backup power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a mud generator is used to provide power to downhole electronics, then power can be generated using mud flow, but the device is prone to stalling and restricts mud flow
Solution Approach 1:
The patent replaces the mud generator's mechanical power generation system with an electrical induction motor system. The induction motor receives electrical power from surface through the drill string and converts it to mechanical rotation, eliminating the need for mud flow-driven mechanical generators. This substitution resolves the stalling issue by providing a more reliable electrical-to-mechanical conversion system that is not dependent on mud flow conditions.
Solution Approach 2:
The patent extracts the power generation function from the mud flow system by introducing a separate electrical power transmission path through the drill string. The induction motor is powered electrically from surface rather than mechanically from mud flow, separating the power generation function from the mud circulation system and eliminating the restriction and stalling problems associated with mud-driven generators.
2Reliability
If batteries are used as backup power for downhole electronics, then power availability is improved, but the capacity is limited
Solution Approach 1:
The patent merges multiple power sources into a unified system: primary electrical power from surface through the drill string, induction motor-driven mechanical power, and battery backup. This combination provides continuous, unlimited power supply while maintaining reliability, as the induction motor system supplements battery capacity rather than relying on batteries alone.
Solution Approach 2:
The drill string serves multiple functions: it transmits drilling mechanics, provides a pathway for electrical power transmission to the induction motor, and enables communication. This multi-functionality allows the system to provide unlimited power through the electrical connection while maintaining drilling operations, overcoming the capacity limitation of battery-only systems.
3Power
If a mud generator is used for power generation, then downhole power can be provided, but mud flow is restricted
Solution Approach 1:
The patent extracts the power generation function from the mud flow path by introducing electrical power transmission through the drill string to an induction motor. This separates the power generation function from mud circulation, allowing full mud flow for cooling and cuttings removal while providing power through the electrical connection, thereby eliminating mud flow restrictions.
Solution Approach 2:
The patent replaces the mechanical mud-driven generator system with an electrical induction motor system powered from surface. This substitution eliminates the physical obstruction in the mud flow path, allowing unrestricted mud flow to continue its essential functions of cooling the drill bit and removing cuttings while power is transmitted electrically through the drill string.
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
Provides consistent power to downhole electronics while minimizing mud flow restrictions, offering a reliable and efficient power solution for drilling operations.
Implementation Method 1
a rotor to generate electrical current responsive to moving in relation to the stator
Data Source
AI summary
In some embodiments, apparatus and systems, as well as methods, may operate to couple a stator to a borehole, and to move a rotor relative to the stator to generate electrical current to power a borehole tool.