Downhole Sensor Cavity for Rotary Tool Force Measurement

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Solution Overview

Problem

Designing rotary tools equipped with sensors that can be accommodated and protected within underground conduits, such as wellbores, while maintaining effective operation and data collection, is challenging due to environmental factors like vibration and abrasive conditions.

Innovation Solution

Incorporating sensor-containing units with a cavity between the exterior portion and the tool body, where sensors like accelerometers, magnetometers, and strain gauges are shielded and protected from drilling fluid and rock cuttings, allowing for accurate measurement of forces and vibrations during contact with the conduit wall.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If sensors are exposed to the external environment for direct measurement, then measurement capability is improved, but sensor reliability deteriorates due to exposure to drilling fluid and rock cuttings

Engineering Contradiction:

Improvemeasurement capabilityVSAvoidsensor reliability

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The tool is divided into separate functional zones: an exterior portion that contacts the wellbore wall for measurement, and an interior portion containing the sensors protected from the harsh environment. The connecting portions link these zones while transmitting mechanical forces, enabling sensors to remain isolated yet still detect external forces accurately.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connecting portions act as intermediaries that transmit forces from the exterior portion to the sensors in the interior portion. This mediator structure allows the sensors to indirectly measure external forces without direct exposure to drilling fluid and rock cuttings, resolving the contradiction between measurement capability and reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If sensors are protected within an interior cavity, then sensor reliability is improved, but measurement precision deteriorates due to shielding from external forces

Engineering Contradiction:

Improvesensor reliabilityVSAvoidmeasurement capability

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The patent replaces direct mechanical contact between sensors and external environment with a mechanical transmission system. The connecting portions transmit forces through mechanical coupling, allowing sensors to measure forces indirectly while remaining protected in the interior cavity, thus maintaining both reliability and measurement precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If the exterior portion has large contact area with conduit wall, then force measurement sensitivity is improved, but device complexity increases due to additional protection structures

Engineering Contradiction:

Improveforce measurement sensitivityVSAvoiddevice complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The exterior portion serves multiple functions: it provides a large contact area with the wellbore wall for sensitive force measurement, protects the sensors from environmental damage, and transmits forces to the sensors through connecting portions. This multi-functionality reduces the need for additional separate protection structures, thereby limiting device complexity while maintaining measurement sensitivity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 reliable data collection and tool navigation by protecting sensors from harsh environments, facilitating precise measurement of forces and vibrations, thus improving the operational efficiency and accuracy of rotary tools in underground conduits.

Implementation Method 1

at least one strain gauge is attached to the connecting portion and is sensitive to distortion of the connecting portion by forces on the exterior portion

Methodology Applied

Scientific EffectStrain measurement: Deformation

Implementation Method 2

sensors like accelerometers, magnetometers, and strain gauges are shielded and protected from drilling fluid and rock cuttings

Methodology Applied

Scientific EffectAcceleration detection: Accelerometer

Implementation Method 3

sensors like accelerometers, magnetometers, and strain gauges are shielded and protected from drilling fluid and rock cuttings

Methodology Applied

Scientific EffectMagnetic field detection: Magnetometer

Data Source

PatentUS11732571B2Downhole tool with sensor set(s) sensitive to circumferential, axial, or radial forces

Publication Date: 2023.08.22 SCHLUMBERGER TECH CORP

AI summary

A rotary tool for operation within an underground borehole or within tubing in a borehole has a tool body and at least one sensor-containing unit attached to the tool body and positioned to contact the conduit wall. The sensor-containing unit includes an exterior portion to contact the borehole or tubing wall and one or more sensors is located in a cavity between the exterior portion and the tool body. The sensor-containing unit may be formed from the exterior portion, an attachment portion for attachment to the tool body, and one or more connecting portions extending between the attachment and exterior portions, with the sensor-containing cavity between the attachment and exterior portions. Possible rotary tools include drill bits, reamers, mills, stabilizers, and rotary steerable systems.