Rotatable Downhole Interconnect Assembly for Stronger Tool Connections
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Solution Overview
Problem
Existing connectors for downhole instruments in oil and gas exploration lack mechanical strength, corrosion resistance, and ease of installation, which are essential for reliable and efficient connection of multiple sensors and tools during directional drilling.
Innovation Solution
A connector system comprising a male and female rotatable assembly with concentric cylinders and electrical conduits, integrated with centralizers and a split coupling mechanism for secure mechanical and electrical connections, along with a tubular fastener for easy assembly, ensuring robust and corrosion-resistant connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional connectors are used for downhole instruments, then installation is simpler, but mechanical strength and corrosion resistance are insufficient
Solution Approach 1:
The connector is divided into separate male and female assemblies, each with distinct components (housings, rotatable connectors, cylinders) that can be manufactured independently and then assembled together, allowing for optimized strength in each segment while maintaining assembly simplicity
Solution Approach 2:
Multiple concentric cylinders are nested within each other in the rotatable connectors, creating a compact yet mechanically robust structure that provides high strength-to-volume ratio while enabling straightforward insertion and connection
2Reliability
If conventional connectors are used for downhole instruments, then installation is simpler, but corrosion resistance is insufficient
Solution Approach 1:
The connector employs composite construction with multiple materials (metal cylinders, epoxy resin machine keys, rubber centralizers, filler materials) that provide enhanced corrosion resistance through material selection and protective layering, while maintaining ease of installation through modular design
3Reliability
If a secure mechanical connection is implemented with multiple components, then connection reliability is improved, but device complexity increases
Solution Approach 1:
Multiple functions are merged into integrated components: the split coupling simultaneously provides mechanical connection and electrical conduit protection, the centralizers provide both alignment and sealing, and the concentric cylinders provide both structural support and rotational functionality, reducing the number of separate parts despite enhanced reliability
4Reliability
If concentric cylinders with electrical conduits are used, then electrical connection reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The concentric cylinders serve multiple purposes: providing structural support for the rotatable connector, creating sealed chambers for electrical conduits, enabling rotational movement, and providing mounting surfaces for electrical contacts, thereby achieving reliable electrical connections without proportionally increasing manufacturing complexity
Data Source
AI summary
An interconnector for connecting downhole instruments includes a male connector assembly and a female connector assembly. The male connector assembly has a first housing and a male rotatable connector that are connected together. The female connector assembly has a second housing and a female rotatable connector. The second housing is adapted to receive the female rotatable connector. The male rotatable connector has a first end having a plurality of cylinders that are sequentially and concentrically connected, and a second end adapted to receive a first plurality of electrical wires, and a first plurality of electrical contacts disposed on the plurality of cylinders. The female rotatable connector has a first end having a cavity having a plurality of steps adapted to receive the plurality of cylinders in the male rotatable connector, and a second end adapted to receive a second plurality of electrical wires.