Downhole Generator Load Switching for DC Auxiliary Power
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Solution Overview
Problem
Existing submersible pumping systems face challenges in providing direct current electricity to downhole auxiliary components, particularly for systems driven by alternating current motors, necessitating an improved system for powering these components.
Innovation Solution
A downhole pumping system with an integrated generator module and load switch that provides power to auxiliary loads, utilizing a load switch to connect and disconnect power based on switch command signals, and includes a charge controller to manage battery charging and discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a heavy-duty power cable with separate conductors is used to supply electricity to the motor, then the motor can be powered effectively, but it becomes difficult to access direct current electricity for downhole auxiliary components
Solution Approach 1:
The patent combines the power supply function and DC electricity generation function into a single integrated system. The generator module converts AC power from the motor into DC power for auxiliary loads, merging two previously separate functions into one compact unit that solves the accessibility problem.
Solution Approach 2:
The generator module acts as an intermediary between the AC power source (motor) and the DC power requirement (auxiliary loads). It converts the AC electricity from the motor into DC electricity, serving as a mediator that enables DC power delivery without requiring separate DC conductors.
2Reliability
If auxiliary components are powered by direct current electricity, then they can operate effectively in the downhole environment, but the system complexity increases when integrating with alternating current motor systems
Solution Approach 1:
The generator module merges the AC motor and DC auxiliary load systems into a single integrated unit. By combining the power conversion function within the motor assembly, the system reduces overall complexity while maintaining reliable DC power supply to auxiliary components.
3Adaptability or versatility
If a generator module is added to provide DC power to auxiliary loads, then power supply capability is improved, but the device complexity increases
Solution Approach 1:
The generator module is integrated directly into the motor assembly, merging the power generation and motor drive functions into a single unit. This integration approach provides versatile AC/DC power supply capability while minimizing the increase in overall system complexity through compact design.
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
Enables efficient and controlled power distribution to downhole auxiliary components, enhancing system functionality and reliability by ensuring power availability to sensors and other equipment.
Implementation Method 1
an electrical generator configured to convert mechanical energy to electrical energy
Data Source
AI summary
A downhole pumping system is configured for producing fluids from a subterranean geologic formation. The downhole pumping system includes an electric motor driven by a motor drive located on the surface, a power cable connected between the motor drive and the electric motor, a pump driven by the electric motor, an auxiliary load, and a generator module driven by the electric motor and configured to provide power to the auxiliary load. The generator module includes an electrical generator and a load switch connected between the electrical generator and the auxiliary load. The load switch is configured to connect and disconnect power to the auxiliary load in response to a switch command signal transmitted by the motor drive. The generator module may also include a battery and charge controller, which can be configured to automatically charge the battery from the generator and provide the load switch with power from the battery.