Downhole Tool Multi-Contact Connector for Reliable Electrical Coupling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current downhole tools face challenges in reliably connecting and operating in harsh downhole environments, requiring improved electrical coupling and mechanical support for efficient operation.
Innovation Solution
A downhole tool connector system featuring a contact member and connector member with redundant contact points and engagement mechanisms, providing both electrical coupling and mechanical support through a housing with pin and box ends, and a plunger connector with multiple connector contacts and a contact spring for secure engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a downhole tool connector system is designed for harsh downhole environments, then reliability of electrical coupling is improved, but device complexity increases
Solution Approach 1:
The connector system is divided into separate functional components: a contact member with multiple contact points, a connector member with corresponding receptacles, and a plunger mechanism. This segmentation allows each component to be optimized for its specific function while maintaining overall reliability in harsh environments.
Solution Approach 2:
The connector member includes pre-positioned engagement features and the plunger is pre-configured to automatically engage the contact member when inserted. This preliminary arrangement ensures reliable electrical coupling is established before full connection is complete, preventing failed connections in harsh downhole conditions.
2Reliability
If multiple contact points and engagement mechanisms are added to ensure reliable connection, then electrical coupling reliability is improved, but ease of operation deteriorates
Solution Approach 1:
Multiple contact points and engagement features are merged into an integrated connector assembly where the plunger mechanism simultaneously engages both mechanical and electrical connection functions. This combining reduces the number of separate operations needed while maintaining reliable multi-point electrical coupling.
Solution Approach 2:
The plunger mechanism is designed to automatically engage the contact member and establish electrical contact without requiring precise manual alignment or multiple adjustment steps. The self-aligning features enable the connector to service itself during assembly, improving ease of operation while maintaining reliability.
3Reliability
If a robust connector system with multiple engagement points is used, then reliability in harsh environments is improved, but manufacturing complexity increases
Solution Approach 1:
The connector components are designed with universal features that serve multiple functions: the plunger provides both mechanical engagement and electrical contact, while the housing structure provides both protection and alignment. This multi-functionality reduces the number of separate parts that need to be manufactured, simplifying production while maintaining robustness for harsh environments.
Data Source
AI summary
A component connector is positioned in downhole tool. The downhole component includes a bulkhead and a receiver positioned in a housing. The component connector includes a contact member positioned in the bulkhead and a connector member in a receiver of the downhole tool. The contact member has an elongate body with a coupling end and a contact end. The connector member has another elongate body having a coupler end and a receptacle end. The connector member has an engager positioned about an outer surface of the connector member to provide selective engagement with the receiver. The coupling end of the contact member and the coupler end of the connector member are connected to electronics in the housing and wherein the receptacle end of the contact member is shaped to electrically receive the contact end of the contact member whereby electronics in adjacent components of the downhole tool are electrically coupled.