Downhole Electromagnetic Core Assembly With Strain-Relief Mesh Housing
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Solution Overview
Problem
Existing downhole telemetry systems, such as mud pulse telemetry, suffer from slow data transmission rates, making it inadequate for real-time transmission of large data quantities. Additionally, wired pipe telemetry systems face premature structural failure due to strain concentration around through-holes in the annular housing of inductive transducers.
Innovation Solution
The proposed solution involves an electromagnetic transducer core assembly with an annular mesh housing that includes strain relief openings to distribute strain induced by stretching, thereby preventing premature structural failure. The transducer assembly features an MCEI core with an embedded annular electrical conductor and incorporates annular bumpers for sealing against downhole conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a through-hole is created in the annular housing for input lead insertion, then electrical connectivity is achieved, but strain concentration occurs around the through-hole causing premature structural failure
Solution Approach 1:
The housing is divided into multiple segments or sections, with the through-hole distributed across segmented regions rather than concentrated in a single location. This segmentation distributes the strain across multiple points, preventing localized stress concentration that would lead to premature failure while maintaining electrical connectivity.
Solution Approach 2:
The housing material or structure is modified locally around the through-hole region to enhance strength and distribute strain. This may include reinforcing ribs, thicker wall sections, or specialized geometric features at the through-hole location that maintain electrical connectivity while preventing strain concentration.
2Manufacturing precision
If the annular housing is stretched to provide rebound force, then positioning accuracy is improved, but strain-induced material failure accelerates
Solution Approach 1:
The housing is pre-stretched or pre-conditioned during manufacturing to establish the desired rebound force and positioning characteristics before service. This preliminary action ensures that the housing achieves accurate positioning while minimizing the strain cycles required during operation, thereby extending service life.
Solution Approach 2:
The material properties or geometric parameters of the housing are modified to optimize the balance between rebound force and strain resistance. This may involve selecting materials with specific elastic properties, adjusting wall thickness, or modifying the cross-sectional geometry to reduce strain concentration while maintaining positioning accuracy.
3Productivity
If traditional wired pipe telemetry systems are used, then data transmission rate increases, but structural reliability decreases due to strain concentration
Solution Approach 1:
The wired pipe telemetry system is divided into modular segments, each with distributed through-holes and strain relief features. This segmentation allows the system to maintain high data transmission rates while distributing mechanical stress across multiple locations, preventing premature structural failure.
Solution Approach 2:
The housing employs composite material construction combining materials with different mechanical properties to achieve both high strength and flexibility. This composite structure maintains the structural integrity required for reliable data transmission while accommodating the strain induced by stretching and rebound actions.
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 enhances the structural reliability and longevity of the transducer devices by distributing strain evenly, potentially increasing the life expectancy by a minimum of 2,000% while maintaining the strength and rebound force of the annular housing.
Implementation Method 1
As current flows through the insulated conductor, a magnetic flux or field is created around the insulated conductor. The MCEI element contains the magnetic flux created by the insulated conductor and prevents energy leakage into surrounding materials.
Implementation Method 2
The annular housing stretches as it is forced into the recess within the mating surface of a downhole component. This stretching action provides a rebound force to return the annular housing to its original position when the force is removed.
Implementation Method 3
Data transmission involves transmitting an electrical signal through an electrical conductor in a first wired pipe, converting the electrical signal to a magnetic field upon leaving the first wired pipe using an inductive transducer at an end of the first wired pipe, and converting the magnetic field back into an electrical signal using an inductive transducer at an end of the second wired pipe.
Data Source
AI summary
An electromagnetic core assembly for power and data transmission in a tool string for downhole construction and production comprising an annular mesh housing defining an annular open channel. A magnetically conductive electrically insulating, MCEI, core is disposed within the annular open channel. An annular electrical conductor is imbedded within the MCEI core, the electrical conductor being connected to ground and to a cable running through a downhole tool. The mesh housing may be at least partially electrically insulating and at least partially electrically conducting. The mesh housing may comprise a metal or a nonmetal or a fabric. The mesh housing may comprise MCEI elements. The mesh size of the housing may be sufficient to at least partially contain an electromagnetic field or flux emanating from the electrical conductor. The MCEI core may comprise a depression in its planar top surface above the electrical conductor. The core may comprise reinforcements.