Downhole Sensor Substrate Integrating Strain Gauges and Temperature Measurement
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Solution Overview
Problem
Current sensor configurations for downhole tools have limitations, including the need for separate calibration of multiple gauges, signal noise due to distance between printed circuit boards (PCBs) and sensors, and inadequate temperature measurement integration, which complicates accurate measurement of weight-on-bit, torque-on-bit, and bending moments.
Innovation Solution
Integration of multiple gauges on a single substrate with a PCB close to the gauges, inclusion of a temperature sensor, and positioning of sensors 180° apart on the collar to accurately measure axial and torsional loads, thereby enhancing measurement accuracy and reducing calibration time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple gauges are disposed separately on the collar, then each gauge can be independently positioned, but multiple separate calibrations are required increasing time and costs
Solution Approach 1:
Multiple gauges are integrated onto a single substrate, allowing them to be calibrated together as one unit rather than individually. This merging of multiple measurement functions into a single calibratable component directly reduces calibration time and operational complexity.
2Measurement precision
If PCB is positioned away from the gauges, then easier assembly is achieved, but signal noise increases due to distance
Solution Approach 1:
The PCB is integrated within the sensor housing in close proximity to the gauges on the substrate. This merging of electronic components with sensing elements minimizes signal transmission distance and reduces noise, improving measurement precision while maintaining assembly feasibility.
3Measurement precision
If temperature sensor is not integrated, then simpler sensor design is achieved, but accurate temperature measurement for operational characteristics is inadequate
Solution Approach 1:
The sensor system is designed to perform multiple measurement functions including mechanical gauges for weight-on-bit and torque-on-bit, plus an integrated temperature sensor. This multi-functional integration enables comprehensive monitoring of drill motor performance characteristics through a single sensor assembly.
4Measurement precision
If sensors are not positioned strategically on the collar, then easier installation is achieved, but accurate measurement of axial and torsional loads is compromised
Solution Approach 1:
Two sensor assemblies are positioned at specific locations on the collar to optimally capture axial and torsional load characteristics. This strategic positioning ensures accurate measurement of drill motor performance while maintaining a straightforward installation process using standard collar mounting procedures.
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
This configuration improves measurement accuracy by reducing signal noise, allows concurrent calibration of sensors, and provides precise temperature readings, facilitating efficient and accurate monitoring of downhole tool operational characteristics, including weight-on-bit, torque-on-bit, and bending moments.
Implementation Method 1
a first sensor including: a first substrate and a plurality of strain gauges disposed on the first substrate and configured to measure axial strains and torsional strains on the collar
Data Source
AI summary
Aspects of the subject technology relate to a sensor for a downhole tool. The downhole tool can include a collar and a sensor. The sensor can be secured to the collar for measuring one or more operational characteristics of the downhole tool during operation of the downhole tool including the performance characteristics of a drill motor. The sensor can include a substrate. The sensor can also include a plurality of strain gauges disposed on the substrate. The plurality of strain gauges can be configured to measure axial strains and torsional strains on the collar for measuring the one or more operational characteristics of the downhole tool.