Downhole Probe Rigid Couplings for Vibration-Resistant Electrical Connections

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Solution Overview

Problem

Downhole probes used in subsurface drilling face reliability issues due to harsh conditions such as high temperatures, vibrations, and pressures, leading to premature failure and increased costs, and there is a need for improved alignment of sensors within the probes and other drill string components.

Innovation Solution

The design of downhole probes with hard-mounted electronic components and modular structures featuring rigid couplings that eliminate flexible wire harnesses, ensuring stable electrical connections and fixed orientations of sensors relative to the probe housing, which enhances reliability and alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If flexible wire harnesses are used to connect electrical components in downhole probes, then ease of assembly is improved, but reliability deteriorates due to vibrations and pressures causing connection failures

Engineering Contradiction:

Improveease of assemblyVSAvoidelectrical connection reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The probe is divided into modular sections with electrical connectors at interfaces, allowing flexible assembly while maintaining reliable connections through standardized rigid coupling mechanisms that prevent relative movement between modules

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Flexible wire harnesses are replaced with rigid electrical connectors and immobilized conductors that are mechanically fixed to prevent movement, substituting the flexible mechanical connection system with a rigid fixed connection system that withstands downhole vibrations and pressures

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of repair

If electronic components are loosely mounted in downhole probes, then ease of repair is improved, but reliability deteriorates due to harsh downhole conditions causing component failure

Engineering Contradiction:

Improvecomponent replaceabilityVSAvoidcomponent stability

Core Design Contradiction:

Ease of repairVSReliability

Solution Approach 1:

Electronic components are organized into modular assemblies that can be replaced as units, maintaining ease of repair while ensuring each component is securely mounted within its module to prevent failure from vibrations and pressures

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Components are pre-mounted and tested in modular assemblies before final installation in the probe, ensuring proper securing and alignment that prevents failure under downhole conditions while maintaining replaceability of entire modules

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If sensors are mounted with flexible connections in downhole probes, then adaptability is improved, but measurement precision deteriorates due to vibrations causing misalignment

Engineering Contradiction:

Improvesensor mounting flexibilityVSAvoidsensor alignment accuracy

Core Design Contradiction:

Adaptability or versatilityVSMeasurement precision

Solution Approach 1:

Flexible sensor mounting connections are replaced with rigid fixed mounting structures that precisely position sensors relative to the probe axis and each other, eliminating vibration-induced misalignment while maintaining adaptability through standardized mounting interfaces

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Different parts of the probe have different mounting characteristics: sensors require rigid fixed mounting for precision, while other components may use standardized interfaces for adaptability, with each mounting method optimized for its specific function

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS9874083B2Downhole probes and systems

Publication Date: 2018.01.23 EVOLUTION ENG

AI summary

Disclosed are downhole probes in which electrical interconnections between different modules are achieved without wiring harnesses. Modules may be coupled to one another and/or to bulkheads in the probe my couplings that provide substantially rigid couplings. The couplings may be configured to connect together only in one orientation. Electrical connectors may be fixed relative to components of the couplings so that the electrical connectors are automatically aligned for connection by the couplings.