Circuit Board Mounting in Confined Downhole Tool Space
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Solution Overview
Problem
Circuit boards in downhole tools face challenges in withstanding harsh conditions such as extreme temperatures and vibrations due to inadequate mounting solutions in confined spaces, leading to potential dislodgment and failure.
Innovation Solution
A mounting assembly comprising a sleeve with deflecting flaps and a housing with a shoulder and groove configuration, along with a threaded nut, securely retains the circuit board within the downhole tool, utilizing a cap to prevent removal and enhance stability under vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a circuit board is mounted in a confined space within a downhole tool, then the tool can provide real-time near-bit information in harsh downhole conditions, but the circuit board is susceptible to dislodgment due to vibrations and shocks
Solution Approach 1:
The mounting assembly incorporates flexible flaps that can deflect dynamically in response to vibration and shock forces. These flaps are designed to flex under impact while maintaining secure retention of the circuit board, allowing the mounting structure to adapt to harsh downhole conditions rather than rigidly resisting all forces.
Solution Approach 2:
The mounting assembly features self-retaining flaps that automatically secure the circuit board through their elastic deformation. When the circuit board is inserted, the flaps deflect and then return to their original position, creating a self-locking mechanism that secures the board without requiring additional fasteners or complex assembly steps.
2Reliability
If material is removed from the tool collar to accommodate the mounting assembly, then the circuit board can be securely mounted, but the mechanical rating of the tool collar is reduced
Solution Approach 1:
The mounting assembly is designed to nest within the existing tool collar structure. The housing and flaps are configured to fit into the confined space of the tool collar without requiring extensive material removal, thereby preserving the structural integrity and mechanical rating of the tool collar while providing secure circuit board mounting.
3Reliability
If a secure mounting solution is implemented for the circuit board, then the circuit board can withstand harsh downhole conditions, but the device complexity increases
Solution Approach 1:
The mounting assembly is divided into distinct functional segments: a housing structure, multiple independent flaps, and a circuit board retention mechanism. Each segment performs a specific function, allowing for modular manufacturing, assembly, and maintenance while providing comprehensive protection and secure mounting of the circuit board.
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 effectively secures the circuit board, enhancing its durability and reliability by preventing dislodgment and maintaining functionality in harsh downhole conditions, while minimizing material removal from the tool collar, thus increasing mechanical rating and reliability.
Implementation Method 1
the plurality of flaps are configured to deflect in response to movement of a portion of the circuit board past a retention feature defined by the flaps and return in response to the portion of the circuit board moving past the retention feature
Data Source
AI summary
Aspects of the subject technology relate to a circuit board mounting assembly for use in a downhole tool. The assembly can include a sleeve comprising a plurality of flaps and a circuit board disposed on the proximal end of the sleeve and secured by the plurality of flaps. The assembly can include a hollow housing comprising a shoulder on an interior surface of the housing at a proximal portion of the housing and a circuit board disposed on the shoulder of the housing. The assembly can further include a groove disposed on the interior surface and a ring disposed within the groove. The assembly can further include a threaded portion on the interior surface extending from a distal end of the housing and a nut threadedly engaged with the threaded portion of the housing. An example method for mounting a circuit board in a downhole tool can include disposing a circuit board on a shoulder of a housing, engaging a periphery of the circuit board, inserting the housing within a cavity of a downhole tool and installing a cap over the cavity to prevent removal of the housing from the downhole tool.