Brushless Servo Actuator for Choke Valve
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Solution Overview
Problem
Traditional actuator systems for choke valves in well drilling, such as pneumatic, hydraulic, and brush motor driven systems, face issues with maintenance complexity, temperature and air quality sensitivity, and rapid wear, leading to increased downtime and potential well blowouts due to inadequate pressure control.
Innovation Solution
A brushless servo motor actuation system with a compact design, continuous position feedback, and a brake mechanism, which is not affected by extreme temperatures or poor air quality, and can be easily maintained by eliminating peripheral components, allowing for precise control and rapid response to motion commands without the need for pressurized fluids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If pneumatic actuated systems are used, then ease of maintenance is improved, but reliability deteriorates due to stick slip phenomenon and sensitivity to air quality and temperature
Solution Approach 1:
The patent replaces the pneumatic mechanical actuation system with an electric motor-driven system. The electric motor eliminates the stick-slip phenomenon inherent in pneumatic systems and removes sensitivity to air quality and temperature conditions, thereby improving reliability while maintaining ease of maintenance through electronic control.
Solution Approach 2:
The patent changes the fundamental operating parameter from pneumatic pressure to electrical power. This parameter change eliminates the adverse effects of poor air quality and extreme temperatures on system performance, while the electric motor provides smooth, controlled motion without the stick-slip characteristics of pneumatic actuators.
2Reliability
If hydraulic actuated systems are used, then reliability is improved compared to pneumatic systems, but device complexity and maintenance requirements increase
Solution Approach 1:
The patent replaces the hydraulic mechanical system with an electric motor-driven system. This substitution eliminates the need for hydraulic fluid, pumps, valves, and associated plumbing, thereby reducing device complexity while maintaining reliable operation through electric control.
Solution Approach 2:
The patent extracts and removes the hydraulic fluid system entirely from the actuator design. By eliminating the hydraulic fluid, pumps, and associated components, the system achieves reliable operation with significantly reduced complexity and lower maintenance requirements.
3Adaptability or versatility
If conventional brush motors are used, then adaptability to environmental conditions is improved, but productivity deteriorates due to brush wear and frequent power cycling
Solution Approach 1:
The patent replaces the brush motor with a brushless direct current (BLDC) motor. This substitution eliminates the brushes that wear out during frequent power cycling, thereby improving productivity and reliability. The BLDC motor maintains adaptability to environmental conditions while eliminating the limiting factor of brush wear.
Solution Approach 2:
The patent eliminates the consumable brushes in the motor system. By using a brushless motor design, there are no short-living components that require replacement due to wear, thereby extending system life and improving productivity without sacrificing environmental adaptability.
4Adaptability or versatility
If traditional multi-component actuator systems are used, then adaptability is improved, but ease of repair deteriorates due to difficulty in identifying failed components
Solution Approach 1:
The patent merges multiple separate components into an integrated actuator assembly. The electric motor, gear reduction mechanism, and valve control are combined into a single unified system, eliminating the need to identify and diagnose individual failed components. This integration maintains adaptability while dramatically improving ease of repair through modular replacement.
Solution Approach 2:
The patent creates a universal actuator module that performs multiple functions within a single integrated design. The electric motor provides both positioning and holding functions, the gear reduction handles both speed reduction and torque multiplication, and the entire assembly can be replaced as one unit, improving ease of repair while maintaining system adaptability.
5Ease of operation
If pneumatic actuators are used, then ease of operation is improved, but manufacturing precision deteriorates due to overshoot and delay in achieving valve set point
Solution Approach 1:
The patent implements feedback control through the electric motor system. The motor controller receives position feedback and adjusts the actuation signal to achieve precise valve positioning without overshoot. This feedback mechanism maintains ease of operation while dramatically improving the precision of achieving the desired valve set point.
Solution Approach 2:
The patent uses dynamic control characteristics of the electric motor to optimize performance. The motor controller can dynamically adjust acceleration, deceleration, and positioning rates to eliminate overshoot and minimize settling time, thereby achieving both ease of operation and high manufacturing precision in valve positioning.
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 brushless servo motor actuation system provides reliable, precise, and efficient control of choke valves, reducing maintenance time and preventing well blowouts by maintaining consistent performance across varying environmental conditions and eliminating the need for complex fluid systems.
Implementation Method 1
brushless servo motor actuation system
Implementation Method 2
brake mechanism
Data Source
AI summary
A compact, axially aligned brushless servo motor actuation unit configured to manipulate a choke valve to control the pressure within a borehole during managed pressure drilling. The actuation unit including a brushless servo, a gear reduction assembly and a planetary roller actuator substantially aligned along a longitudinal axis and housed within a tubular housing, the gear reduction assembly defining a hollow core sized to enable a portion of a roller screw of the planetary roller actuator to pass therethrough for the purpose of reducing the overall length of the actuation unit along the longitudinal axis.