Composite Transmission Element for Downhole Data and Power
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Solution Overview
Problem
Downhole drilling operations face challenges with electronic equipment due to extreme temperatures, shock, vibration, and corrosive drilling mud, which affect signal communication, generation, and conveyance, necessitating improved protection and communication techniques.
Innovation Solution
A composite transmission element with an enhanced magnetically conductive electrically insulating polymer carrier, embedded with an electrical conductor, is used to facilitate high-speed data communication and power transmission through inductive coupling, suitable for extreme downhole conditions, and includes features like anti-rotation tabs, perforations, and a polymeric carrier design that can be molded using various methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If electronic equipment is placed downhole to perform measurements and data collection, then productivity and efficiency of drilling operations are improved, but the equipment is exposed to extreme temperatures, shock, vibration, and corrosive drilling mud that damage reliability
Solution Approach 1:
The patent introduces an inductive coupling system as an intermediary between electronic equipment and the downhole environment. The coupling system includes a first inductive coupler in communication with the electronic equipment and a second inductive coupler in communication with the drilling mud environment, allowing energy and data transfer without direct electrical connection, thus protecting the equipment from harsh conditions while maintaining functionality
Solution Approach 2:
The patent employs a polymeric carrier that encapsulates the first inductive coupler, providing physical protection against shock, vibration, and corrosive drilling mud. The polymeric material acts as a flexible shell that shields the electronic components while allowing the device to function in the downhole environment
2Loss of information
If conventional transmission lines are used for data communication downhole, then signal conveyance is achieved, but signal communication is affected by extreme temperatures, shock, and vibration
Solution Approach 1:
The patent replaces conventional mechanical electrical connection systems with an inductive coupling system that uses electromagnetic fields for energy and data transfer. This substitution eliminates direct electrical contacts that are vulnerable to shock and vibration, using instead a magnetic field-based transmission mechanism that is inherently more resistant to mechanical disturbances
Solution Approach 2:
The inductive coupling system serves as an intermediary transmission mechanism between the electronic equipment and the external environment, allowing signal communication without direct electrical exposure to harsh conditions. The magnetic coupling enables data transfer while isolating the electronics from temperature extremes and mechanical stress
3Reliability
If electronic circuitry is protected by placing it in a sonde lowered by cable, then protection from downhole conditions is achieved, but the system complexity and operational limitations increase
Solution Approach 1:
The patent integrates multiple functions into a single downhole device that combines electronic circuitry for measurements, inductive coupling for energy and data transfer, and polymeric encapsulation for protection. This multi-functional integration eliminates the need for separate sonde and cable systems, reducing overall system complexity while maintaining protection and communication capabilities
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 provides reliable high-speed data communication and power transmission in harsh downhole environments, protecting electronic components from extreme conditions and ensuring efficient operation of drilling equipment.
Implementation Method 1
The electrical conductor may be suitable for producing an electromagnetic field or flux within the carrier when energized by an electric signal
Implementation Method 2
The carrier may comprise an enhanced magnetically conductive electrically insulating, MCEI, polymer. The enhanced MCEI polymer may comprise a volume of MCEI particles in sufficient quantity to allow the polymeric carrier to transmit the electromagnet field to an adjacent carrier
Data Source
AI summary
A tool string composite transmission element comprising a composite polymeric carrier comprising an electrical conductor embedded therein. The conductor may be connected to ground and to a cable and may be suitable for producing an electromagnetic field within the carrier when energized. The conductor may comprise a tab that may align with a slot within the carrier to prevent rotation of individual carrier fragments or segments strung along the conductor. The carrier may comprise a volume of MCEI particles sufficient to allow the carrier to transmit the electromagnet field to an adjacent carrier. The transmitted field may be used to convey data and power. The carrier may comprise an annular or linear configuration. Also, the carrier may comprise a bumper for securing the carrier within a groove within a tool within the tool string. The carrier may comprise a depression in its outer top surface above the electrical conductor.