Integrated Sensor Module Cable Tension Measurement
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Solution Overview
Problem
In downhole operations, the increasing number of sensor modules in cable arrays leads to complex and heavy mechanical connections, making it difficult to measure cable tension directly in integrated module cables, as the tension force is not applied directly to the sensor module, complicating the detection of cable stacking and friction issues.
Innovation Solution
A measurement system using two strain gauges mounted orthogonally and parallel to the central axis of a tension member within the integrated sensor module housing, allowing for the determination of cable tension by correlating compression stress on the module housing with the applied tension, while accounting for downhole pressure effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If integrated sensor modules are used in cable arrays, then the number of mechanical connections is reduced and tool weight is decreased, but cable tension cannot be readily measured because tension force is not applied directly to the integrated sensor module
Solution Approach 1:
The patent introduces a tension member as an intermediary element that transmits the cable tension force to the integrated sensor module. The strain gauges are mounted on this tension member, which acts as a mediator to convert the cable tension into measurable strain on the module housing, enabling indirect measurement of cable tension without direct force application to the sensor module.
Solution Approach 2:
The patent replaces direct mechanical force measurement with strain measurement. Instead of measuring cable tension directly through mechanical means, the system uses strain gauges to measure the strain induced in the tension member and module housing, then computes the cable tension parameter from these strain measurements, substituting a mechanical measurement system with a strain-based measurement system.
2Productivity
If the number of sensor modules in cable arrays is increased, then data quality is improved and operation time is reduced, but the mechanical connections become more complex and heavier
Solution Approach 1:
The patent merges the sensor module with the cable structure to create an integrated sensor module. This integration eliminates the need for separate mechanical connections between individual sensor modules and the cable, as each module is directly integrated into the cable array. The strain gauges are mounted directly on the module housing, combining the sensing function with the structural element.
3Measurement precision
If strain gauges are mounted on the integrated sensor module, then cable tension can be measured, but the measurement must account for both tension-induced compression and downhole pressure effects
Solution Approach 1:
The patent segments the measurement function into two distinct strain gauge orientations: one gauge measures the combined effect of tension and pressure, while the other gauge (mounted orthogonally) measures primarily the pressure effect. By separating the measurement into different orientations, the system can isolate and compute the cable tension parameter by differentiating between tension-induced compression and pressure effects through computational analysis of the two strain measurements.
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
Enables accurate measurement of cable tension and pressure, facilitating the detection of cable stacking locations and reducing the need for complex mechanical connections, thereby optimizing the efficiency and weight of downhole array tools.
Implementation Method 1
a first strain gauge mounted perpendicularly along a central axis of a tension member and a second strain gauge mounted a distance away from but parallel to the central axis of the tension member. The first strain gauge and the second strain gauge may be configured to measure strain induced by at least one of tension or downhole pressure.
Data Source
AI summary
A measurement device, method, and integrated module for a cable array for determining a downhole parameter are provided. The measurement device, method and integrated module may include a first strain gauge mounted perpendicularly along a central axis of a tension member and a second strain gauge mounted a distance away from but parallel to the central axis of the tension member. The first strain gauge and the second strain gauge may be configured to measure strain induced by at least one of tension or downhole pressure. In addition, the measurements from the first and the second strain gauge may be used to determine the cable tension for the integrated module of the cable array.