Downhole Actuator Impact Mechanism for High Torque
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Solution Overview
Problem
Downhole electrical tools face limitations in providing adequate torque to overcome static friction and obstructions due to power restrictions and infrastructure challenges, leading to inefficient operation of valves and tools like E-ICVs.
Innovation Solution
An actuator assembly employing an impact mechanism with a spring, hammer, and anvil, which stores kinetic energy and delivers it as high instantaneous torque to overcome friction and obstructions, using a configuration similar to impact drivers or hammer drills to facilitate movement of sliding sleeves in E-ICVs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If traditional motors are used to provide torque for E-ICV operation, then power transmission losses occur and adequate torque cannot be delivered, but increasing motor power would exceed downhole power restrictions and infrastructure limitations
Solution Approach 1:
The motor operates in periodic cycles, alternating between high-speed rotation for kinetic energy storage and impact delivery phases. This periodic operation allows the motor to deliver high torque impacts without requiring continuous high power consumption, resolving the contradiction between force delivery and power consumption.
Solution Approach 2:
The system dynamically switches between two operational modes: a high-speed rotation mode for energy accumulation and an impact delivery mode for force application. This dynamic operation allows the motor to optimize its power consumption based on the immediate operational requirements, delivering adequate torque when needed without excessive continuous power usage.
2Force
If high torque is provided to overcome static friction and obstructions, then valve operation is achieved, but operating speed becomes low and unacceptable to end users
Solution Approach 1:
The motor alternates between high-speed rotation phases (for rapid positioning) and impact delivery phases (for overcoming friction). This periodic action allows the system to achieve both high operating speed during rotation and high torque during impact, resolving the contradiction between speed and torque requirements.
Solution Approach 2:
The system dynamically adjusts its operational characteristics based on the immediate need: high speed when the valve is moving freely, and high torque when obstructions or static friction must be overcome. This dynamic adaptation allows the motor to optimize both speed and torque performance across different operational conditions.
3Speed
If low torque with high speed is used, then operating speed is improved, but the E-ICV sleeve or ball valve cannot be moved
Solution Approach 1:
The motor performs periodic high-speed rotation to position the valve quickly, then delivers periodic impact pulses to overcome static friction and move the valve. This periodic combination of high-speed rotation and impact delivery resolves the contradiction by providing both speed and torque at different phases of operation.
Solution Approach 2:
The system dynamically switches between high-speed operation for positioning and high-torque impact for valve movement. This dynamic operation allows the motor to optimize speed when the valve is moving and torque when the valve needs to be actuated, resolving the contradiction between speed and force delivery.
4Force
If additional power is provided to develop more torque, then torque capability is improved, but operating costs increase and power transmission losses worsen
Solution Approach 1:
The motor operates periodically, accumulating kinetic energy during high-speed rotation and delivering it through impact pulses. This periodic operation reduces the average power transmission requirements compared to continuous high-torque operation, thereby reducing power transmission losses while maintaining adequate torque capability when needed.
Solution Approach 2:
The system dynamically optimizes its power consumption by switching between high-speed rotation (lower torque, higher speed) and impact delivery (high torque, lower speed) modes. This dynamic operation minimizes average power transmission losses while delivering adequate torque only when required for valve actuation, rather than maintaining high torque continuously.
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 impact mechanism allows for high torque and efficient operation of downhole tools by providing a rapid, high-force actuation that traditional motors struggle to achieve, effectively breaking static friction and removing debris, thereby enhancing the functionality of downhole tools.
Implementation Method 1
a spring and a hammer, the spring adjacent to the hammer, the hammer operable to compress the spring, the spring operable to expand
Implementation Method 2
The spinning hammer stores the kinetic energy and utilizes the kinetic energy to produce an impact against the anvil
Implementation Method 3
The hammer striking the anvil produces actuation forces at a linear actuator... producing a very high instantaneous torque
Data Source
AI summary
Systems and methods of the present disclosure relate to actuator assemblies for downhole tools. An actuator assembly comprises a motor, a spring and a hammer. The spring is adjacent to the hammer, and the hammer operable to compress the spring. The spring is operable to expand. The assembly also includes an anvil adjacent to the hammer. The anvil is operable to move a portion of the downhole tool.