Downhole Sensor Carrier With Inductive Coupler
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Solution Overview
Problem
The deployment of permanent electronic equipment in wellbores is hindered by powering issues and the difficulty in retrieving equipment that fails, due to the harsh environment and long lifecycle requirements, which existing technologies have not adequately addressed.
Innovation Solution
A carrier device with inductive couplers and power electronics is designed to be installed downhole, allowing for the deployment of prototype sensors that can be powered and communicate wirelessly, and can be easily retrieved for inspection and replacement, with the option to connect different prototype devices as needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If permanent electronic equipment is deployed in wellbores, then monitoring capability is improved, but powering and retrieval difficulty worsen
Solution Approach 1:
The system divides the monitoring function into permanent infrastructure components (coupler portions in the wellbore) and temporary sensor units (carried on fishing line). This segmentation allows the permanent parts to provide stable power and communication while the temporary parts can be easily deployed and retrieved, resolving the contradiction between monitoring reliability and operational ease.
Solution Approach 2:
The patent introduces an intermediary carrier system (fishing line with sensor carriers) that mediates between the permanent wellbore infrastructure and the sensors. This intermediary enables easy deployment and retrieval of sensors without requiring permanent installation, thus improving ease of operation while maintaining monitoring capability through the permanent coupler portions.
2Duration of action of moving object
If sensors are deployed for long-term monitoring, then data collection is improved, but equipment failure risk increases
Solution Approach 1:
The patent employs disposable or replaceable sensor carriers that can be easily deployed and retrieved. If a sensor fails after extended operation, the entire carrier can be replaced rather than repairing the failed component, reducing the impact of equipment failure on long-term monitoring projects and enabling continuous data collection over extended periods.
Solution Approach 2:
The system allows for discarding failed sensor carriers and recovering successful ones for reuse. The permanent coupler portions in the wellbore can continue to function while sensor carriers are exchanged as needed, enabling long-term monitoring while managing equipment failure risk through replacement rather than repair of permanent installations.
3Ease of operation
If inductive coupling is used for power transfer, then wireless power transmission is achieved, but coupling precision requirements worsen
Solution Approach 1:
The patent uses inductive coupling between coils positioned in the wellbore and on the sensor carrier. By designing the coils with sufficient size and positioning tolerance, the system achieves wireless power transmission that is relatively insensitive to precise alignment, reducing manufacturing precision requirements while maintaining ease of operation.
Solution Approach 2:
The system compensates for misalignment in inductive coupling through design choices such as using larger coil dimensions, adjusting coil spacing, or incorporating alignment tolerance in the mechanical design. These countermeasures offset the precision requirements, allowing wireless power transmission to proceed effectively despite variations in coupling alignment.
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
Enables the extended operation of sensors in wellbores for weeks, months, or years, facilitating the evaluation and potential long-term use of prototype devices, and allows for the retrieval and redesign of equipment based on performance and aging, thereby overcoming the challenges of equipment failure and harsh conditions.
Implementation Method 1
Inductive coupling involves transfer of a time-changing electromagnetic signal or power that does not rely upon a closed electrical circuit, but instead performs the transfer wirelessly. For example, if a time-changing current is passed through a coil, then a consequence of the time variation is that an electromagnetic field will be generated in the medium surrounding the coil. If a second coil is placed into that electromagnetic field, then a voltage will be generated on that second coil, which is referred to as the induced voltage.
Data Source
AI summary
A carrier device is provided for temporary installation downhole in a well. The carrier device is a robust device that is divided by a pressure bulkhead into a first section having an inductive coupler, power electronics, and a telemetry unit, typically all formed using multi-chip-module type electronics, and a second section with at least one test device typically using printed circuit board technology that may include sensors or transducers coupled to a communications bus and/or a power line that extends to the first section via the pressure bulkhead. The carrier further includes a mechanism that permits the carrier to be pulled out of the wellbore, and may include a mechanical locating element, typically adjacent the inductive coupler that permits the carrier to be located in the wellbore so that the inductive coupler will be located adjacent an inductive coupler in, on, or behind a liner or casing of the wellbore.