Charge Tube Assembly Interlocking Design
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Solution Overview
Problem
Existing perforating gun systems face issues with detonation failure, poor ergonomics during assembly, and high manufacturing costs, primarily due to complex assembly requirements and the need for external fasteners.
Innovation Solution
The proposed solution involves a perforating tool assembly with a charge tube assembly that includes a charge tube, a detonator housing, and an end alignment, featuring interlocking joining features, a skeletonized body for material reduction, and a grounding clip to improve electrical grounding and prevent detonation failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional charge tube assembly with external fasteners is used, then structural strength is maintained, but device complexity and manufacturing cost increase
Solution Approach 1:
The charge tube is integrated directly with the gun body through injection molding, merging two previously separate components (charge tube and gun body) into a single unified structure. This eliminates the need for external fasteners and reduces assembly complexity while maintaining structural integrity through the molded-in connection.
Solution Approach 2:
The gun body is designed to serve multiple functions: it provides structural housing, integrates the charge tube mounting, and incorporates grounding features. This multi-functionality reduces the number of separate components needed and simplifies the overall assembly while maintaining all necessary structural and functional requirements.
2Ease of manufacture
If traditional assembly methods are used, then manufacturing robustness is achieved, but manufacturing cost and assembly time increase
Solution Approach 1:
The charge tube and gun body are combined into a single injection-molded component, reducing the number of parts that need to be manufactured, stored, and assembled. This integration simplifies the manufacturing process and reduces assembly time while maintaining production robustness.
Solution Approach 2:
The charge tube is pre-integrated into the gun body during the injection molding process itself, rather than being assembled separately afterward. This preliminary integration action eliminates subsequent assembly steps and reduces the complexity of the manufacturing workflow.
3Reliability
If conventional grounding methods are used, then electrical connection is achieved, but reliability against detonation failure decreases
Solution Approach 1:
The grounding feature is integrated directly into the gun body structure through the injection molding process, combining the grounding function with the structural housing. This eliminates the need for separate grounding components or complex grounding systems while improving reliability through consistent electrical connection.
Solution Approach 2:
The gun body structure itself provides the grounding path through its conductive material and integrated design, rather than requiring external grounding components. The structure serves its own grounding function, ensuring reliable electrical connection for detonation initiation.
Data Source
AI summary
In general, in one aspect, embodiments relate to a charge tube assembly that includes a charge tube, a detonator housing interlocked with the charge tube, an end alignment interlocked with the charge tube, and a detonation cord extending from the detonator housing to the charge tube.