Downhole Power Control Module for Shock-Resistant Torque Delivery
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Solution Overview
Problem
Conventional downhole setting tools are costly, reliant on surface power, vulnerable to jarring events, and lack compactness, making them inefficient and expensive to operate.
Innovation Solution
A power control module for downhole tools that includes a battery pack, an electronic control circuit, and a switch, allowing for autonomous power management and compact design, reducing reliance on surface power and enhancing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional setting tools use surface-powered electrical motors, then rotational output can be generated, but the tools become costly and vulnerable to power line failures
Solution Approach 1:
The power supply system is segmented into modular components: a removable battery pack containing multiple battery cells, a power control module with electronic control circuit, and connection interfaces. This segmentation allows the battery pack to be independently replaced or serviced without affecting other tool components, improving reliability while managing complexity through standardized interfaces.
Solution Approach 2:
The downhole tool incorporates its own power source (battery pack) and control system, enabling it to operate autonomously without continuous surface power supply. The electronic control circuit automatically manages battery power distribution to the motor and other components, allowing the tool to service itself regarding power management and reducing dependence on complex surface power transmission systems.
2Force
If conventional setting tools use reduction gear boxes, then rotational speed can be reduced and torque increased, but the tools become vulnerable to jarring events and less compact
Solution Approach 1:
The power control module incorporates protection circuitry that detects abnormal conditions (such as excessive current draw indicating jarring or stall conditions) and automatically disconnects power to the motor before damage can occur to the gearbox or other mechanical components. This beforehand protection enhances reliability by preventing catastrophic failures from transient jarring events.
3Productivity
If conventional setting tools are designed with full power systems, then operational capability is sufficient, but the tool length increases and running costs increase
Solution Approach 1:
The power control module provides dynamic power management by selectively activating only those components and functions that are currently needed for the specific operational task. The electronic control circuit can adjust motor power levels, activate auxiliary systems only when required, and put systems into low-power or standby modes when not in use. This dynamic operation maintains full operational capability when needed while reducing the effective size and power consumption during normal operation, thereby reducing tool length requirements and running costs.
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 solution provides a cost-effective, compact, and reliable means to generate axial and rotational forces downhole, reducing operational costs and improving tool performance by enabling independent power operation and enhanced shock resistance.
Implementation Method 1
a battery pack; and an electronic control circuit for controlling operation of at least the battery pack
Data Source
AI summary
A downhole tool (1) comprises a power control module (20), which includes a battery pack (22) for supplying power to components of the tool, and an electronic control circuit (24) for controlling the supply of power by the battery pack. The electronic control circuit (24) and battery pack (22) are contained within a housing (26) that allows their insertion and removal as a single unit. The tool (1) also comprises an electric motor (104) for powering a gear assembly (210), and a braking system comprising an electrical and a magnetic brake for braking the motor (104) when required. The gear assembly (210) comprises two or more stages (222, 232, 242, 252, 262), each having a sun gear (223, 233, 243, 253, 263) with a respective diameter, and each sun gear 223, 233, 243, 253, 263 having a raised convex dimple (223LD, 233UD, 233LD, 243UD) that is in constant touching contact with the adjacent sun gear's (223, 233, 243, 253, raised 263) convex dimple (223LD, 233UD, 233LD, 243UD), allowing load experienced by the tool (1) to be transferred along a load path including the dimples (223LD, 233UD, 233LD, 243UD), reducing vibrations and shocks.