Bulkhead Electrical Connector with Pivotable Contact for Downhole Sealing
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Solution Overview
Problem
Existing bulkhead assemblies in downhole tools face challenges in maintaining a pressure seal while allowing for electrical connections, particularly in high-pressure environments, due to issues with wired connections that can be compromised during assembly, leading to intermittent or failed electrical contacts.
Innovation Solution
A bulkhead assembly with a pivotable electrical contact component that includes a conductive fixed body and springs, allowing the electrical contact to pivot without compromising the pressure seal, and a ground apparatus that can pivot to prevent wire damage, ensuring continuous electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wired electrical connections are used to pass signals from surface to initiators, then electrical connectivity is achieved, but the connections are easily twisted and crimped during assembly leading to intermittent or failed electrical contact
Solution Approach 1:
The patent replaces wired mechanical electrical connections with a wireless electrical connection system. The wireless initiator head contains an initiator that can be triggered without physical wire connections, eliminating the mechanical twisting and crimping issues that occur during assembly of wired connections.
Solution Approach 2:
The patent extracts the electrical connection requirement from the physical assembly process. By using wireless initiation, the electrical connection is no longer a physical component that needs to be manually connected through the gun assembly, removing it from the assembly sequence and eliminating associated reliability issues.
2Reliability
If ground wires are manually connected to electrical wires and hardware components, then ground contact is achieved, but the wires become torn, twisted and crimped leading to compromised electrical connection
Solution Approach 1:
The patent eliminates manual ground wire connections by using a wireless initiation system. The wireless initiator head does not require ground wires to be manually connected to hardware components, thereby preventing the mechanical damage that occurs during such connections.
3Strength
If threaded insertion of components is used during assembly, then components are securely connected, but the rotating assembly compromises electrical ground wires
Solution Approach 1:
The patent replaces the threaded mechanical connection system with a wireless initiation system. The wireless initiator head can be installed without threaded assembly operations, eliminating the rotating motion that compromises electrical ground wires while maintaining secure component connection through alternative means.
4Reliability
If manual wiring of live explosives is performed, then electrical connections are established, but safety issues arise from physical handling
Solution Approach 1:
The patent replaces manual wiring operations with a wireless initiation system. The wireless initiator head can be installed and configured without physically handling or connecting wires to live explosives, eliminating the safety hazards associated with manual wiring while maintaining the ability to establish electrical connections for initiation.
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 maintains a pressure seal and ensures reliable electrical connectivity even in high-pressure environments, reducing the risk of wire damage and improving assembly efficiency by allowing the electrical contact to pivot and the ground apparatus to rotate without compromising the connection.
Implementation Method 1
A first spring may be provided in the bore between the first contact surface and the first electrical contact, and the first spring may be in contact with the first contact surface and the first electrical contact
Data Source
AI summary
An electrical connector may include a connector body extending along a longitudinal axis, a first electrical contact provided at a first end of the connector body, a first aperture provided in the first end of the connector body, a bore provided in an interior of the connector body and connected to the first aperture, and a conductive fixed body provided within the bore. The conductive fixed body may include a first contact surface on a first side of the conductive fixed body facing the first electrical contact along the longitudinal axis. A first spring may be provided in the bore between the first contact surface and the first electrical contact, and the first spring may be in contact with the first contact surface and the first electrical contact.