Downhole Sensor Substrate Integrating Strain Gauges and PCB
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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 operational characteristics like 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 bending moments, reducing signal noise and enabling concurrent calibration of the sensor system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple gauges are used to measure operational characteristics, then measurement capability is improved, but calibration complexity and time increase
Solution Approach 1:
Multiple strain gauges are integrated onto a single substrate, allowing them to be calibrated simultaneously as one unit rather than individually. This merging of multiple measurement elements into a single calibratable component directly reduces calibration time while maintaining the ability to measure multiple operational characteristics including weight-on-bit, torque-on-bit, and bending moments
2Ease of manufacture
If PCB is placed away from sensors, then ease of assembly is improved, but signal noise increases
Solution Approach 1:
The printed circuit board (PCB) is integrated within the sensor assembly itself, placing the signal processing electronics in close proximity to the strain gauges. This integration eliminates long signal transmission paths that would introduce noise, while the modular sensor design maintains ease of assembly as a complete unit
3Measurement precision
If temperature sensor is added, then temperature measurement capability is improved, but device complexity increases
Solution Approach 1:
The temperature sensor is integrated onto the same substrate as the strain gauges, sharing the common mounting platform and signal conditioning circuitry. This consolidation adds temperature measurement capability while minimizing the increase in overall device complexity through shared infrastructure
Solution Approach 2:
The substrate serves multiple functions: it mounts the strain gauges for mechanical measurements and the temperature sensor for thermal measurements. This multi-functional substrate design allows diverse measurement capabilities without proportionally increasing device complexity
4Measurement precision
If sensors are positioned 180° apart, then bending moment measurement accuracy is improved, but installation complexity increases
Solution Approach 1:
The sensor system is divided into separate modular sensor units that can be independently positioned at 180° intervals on the collar. Each sensor unit is self-contained and can be installed separately, reducing the overall installation complexity while maintaining the geometric configuration necessary for accurate bending moment measurements
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 enhances measurement accuracy, reduces calibration time and costs, and provides more precise operational data for downhole tools, including improved temperature readings and bending moment measurements.
Implementation Method 1
a first plurality of strain gauges disposed on the first substrate and configured to measure axial strains and torsional strains on the collar that are transferred to the first substrate
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. 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.