Downhole Collar Coils for Power and Telemetry Without Crossover Wires

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Solution Overview

Problem

Conventional downhole turbines in oil and gas wellbore operations require complex seals and crossover wires to transfer power and data, which complicates the design and functionality of measurement-while-drilling (MWD) and logging-while-drilling (LWD) tools.

Innovation Solution

A downhole power and communications system where coils are embedded within the collar of the turbine, eliminating the need for crossover wires and complex seals by using a rotor with radially-extending blades and a stator configuration that generates power from fluid flow, with a telemetry system and power storage device integrated to enhance data transmission and tool operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If probe-based turbines with internal coils are used, then power can be generated downhole, but complex seals and crossover wires are required

Engineering Contradiction:

Improvedownhole power generationVSAvoidseals and crossover wires

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The invention extracts the power-generating coils from the probe housing and embeds them directly into the collar structure. This eliminates the need for crossover wires that would otherwise be required to transfer power from the probe to the collar, thereby reducing mechanical complexity while maintaining downhole power generation capability

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention merges the collar and stator functions by embedding the coils directly into the collar. This integration eliminates the need for separate seal assemblies and crossover wire mechanisms, simplifying the overall system while enabling direct power transfer to MWD/LWD tools

Inventive Principle:

Principle #5Merging (Combining)

2Use of energy by moving object

If crossover wires are used to transfer power and data, then power transmission is enabled, but mechanical components and seals are complicated

Engineering Contradiction:

Improvepower transmissionVSAvoidmechanical components

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The invention replaces the mechanical crossover wire system with an electromagnetic induction system. The collar acts as a stator with embedded coils that generate power through electromagnetic induction when exposed to the magnetic field from the rotor, eliminating the need for mechanical power and data transmission components

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If probe housing configuration is used, then MWD/LWD tools can be housed, but power transfer to collar requires complex mechanisms

Engineering Contradiction:

Improvetool housing capabilityVSAvoidpower transfer mechanism

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The invention changes the spatial arrangement by moving the power-generating coils from the probe housing dimension to the collar dimension. This dimensional shift allows MWD/LWD tools to remain housed in the probe while power is generated and transferred through the collar, eliminating the need for complex inter-dimensional power transfer mechanisms

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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

This configuration simplifies the design by eliminating the need for crossover wires and complex seals, improving the reliability and efficiency of power transmission and data communication in downhole tools, while allowing for robust operation during drilling and logging operations.

Implementation Method 1

a rotor portion of the probe also generally includes radially-extending blades adapted to rotate in response to an axial flow of fluid through the internal passage of the collar

Methodology Applied

Scientific EffectFluid flow:

Implementation Method 2

one or more permanent magnets connected to the rotor, the one or more permanent magnets generating a magnetic field; and a coil connected to the collar and adapted to generate electric power from the rotating magnetic field

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS20240344429A1Downhole power and communications system(s) and method(s) of using same

Publication Date: 2024.10.17 GAJIC BOSKO

AI summary

Apparatus, method(s), and system(s) according to which electric power is generated in one or more coils by rotating a magnetic field generated by one or more permanent magnets. The one or more coils are connected to a collar. The collar is positioned downhole in an oil and gas wellbore. The one or more permanent magnets are connected to a rotor positioned within an internal passageway of the collar. A fluid is communicated along the internal passageway of the collar. The rotor, and thus the magnetic field generated by the one or more permanent magnets, are rotated using the fluid communicated along the internal passage.