Downhole Power Module and Gear Train for Shock-Resistant Setting Tools
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Solution Overview
Problem
Conventional downhole setting tools are costly, reliant on surface power, and vulnerable to jarring events, requiring expensive and time-consuming retrieval trips if issues occur, and lack compactness, which increases operational costs and risks.
Innovation Solution
A power control module with a battery pack and electronic control circuit that can be mounted and removed as a single unit, providing autonomous power to downhole tools, including a magnetic brake system to prevent unwanted rotation, and a gearbox design with convex dimple contact points to reduce friction and stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional setting tools use surface-powered electrical motors, then the tools can operate downhole, but they require expensive and time-consuming retrieval trips if power issues occur
Solution Approach 1:
The patent extracts the power source from the surface and places a battery pack within the downhole tool itself. This allows the tool to operate autonomously downhole without relying on surface power delivery, eliminating the need for retrieval trips when power issues occur and significantly improving operational reliability.
Solution Approach 2:
The downhowl tool becomes self-sufficient by incorporating its own battery pack and power management system. The tool can independently generate and manage its own power supply, controlling motor operation and braking without external surface intervention, thereby eliminating retrieval trips for power-related issues.
2Reliability
If conventional setting tools use surface-powered electrical motors, then the tools can operate downhole, but they incur high costs for power delivery and retrieval operations
Solution Approach 1:
The patent extracts the power source from the surface infrastructure and relocates it to the downhowl tool as an integrated battery pack. This eliminates the need for expensive surface power delivery systems and reduces operational costs associated with power management and retrieval operations.
Solution Approach 2:
By making the tool self-powered with an integrated battery pack and power control module, the system eliminates dependency on costly surface power infrastructure and retrieval operations, significantly reducing overall operational costs while maintaining reliability.
3Power
If conventional gear boxes are used in downhowl tools, then they can provide rotational output, but they cannot cope with significant jarring events
Solution Approach 1:
The patent incorporates a magnetic brake system that can be activated beforehand to control and dampen jarring events before they damage the gear box. The magnetic brake provides a controlled resistance that cushions shock loads, protecting the rotational output mechanism from damage during jarring events while maintaining operational reliability.
4Reliability
If downhowl tools are designed with full power systems, then they can operate autonomously, but they increase in size and complexity
Solution Approach 1:
The patent segments the power system into modular components: a battery pack, a power control module with motor driver, and a magnetic brake system. Each component performs a specific function and can be independently managed, reducing overall system complexity while enabling autonomous operation. The modular design allows for efficient space utilization and simplified maintenance.
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
Enhances tool reliability and safety by ensuring continuous operation without surface power, reduces maintenance needs, and achieves a more compact design, thereby lowering costs and operation time.
Implementation Method 1
a battery pack; and an electronic control circuit for controlling operation of at least the battery pack
Implementation Method 2
A power control module with a battery pack and electronic control circuit that can be mounted and removed as a single unit, providing autonomous power to downhowl tools, including a magnetic brake system to prevent unwanted rotation
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, 263) raised 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.