Downhole Sub Battery Charger Using Triboelectric Motion
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Solution Overview
Problem
In oil field operations, the limited physical dimensions and extreme conditions within subs strain battery capacity, making it difficult to provide reliable power to downhole electronics.
Innovation Solution
A sub for a pipe assembly with a mandrel containing a battery charger and supercapacitors that utilize the triboelectric effect to generate electrical charge from movement, increasing battery capacity by converting mechanical motion into electrical energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a storage battery is used to power downhole electronics in a sub, then the electronics can operate, but the battery capacity is strained due to limited physical dimensions and extreme conditions
Solution Approach 1:
The patent combines a storage battery with a battery charger that converts mechanical energy to electrical energy. The charger includes a generator coupled to a drive shaft, allowing the system to both store and generate electrical energy. This merging of energy storage and energy generation functions resolves the contradiction by providing multiple sources of power within the constrained sub volume.
Solution Approach 2:
The battery charger is designed to automatically charge the battery during drilling operations by converting mechanical energy from the drill string's rotation or vibration into electrical energy. The system serves itself by using the operational motion of the drill string to generate power, eliminating the need for external charging equipment and maximizing energy availability within the limited sub volume.
2Reliability
If a storage battery is used to power downhole electronics in a sub, then the electronics can operate, but access to the sub is difficult under extreme heat and pressure conditions
Solution Approach 1:
The battery charger automatically charges the battery during drilling operations without requiring human intervention or access to the sub. The system uses the mechanical energy from the drill string's operation to generate electrical energy, which is then stored in the battery. This self-charging mechanism ensures continuous power supply reliability while eliminating the need for difficult access to the sub under extreme conditions.
Solution Approach 2:
The battery is pre-charged before being installed in the sub, and the charger is designed to automatically recharge it during operations. This preliminary preparation and automatic recharging ensure that the electronics have reliable power supply without requiring access to the sub during extreme heat and pressure conditions.
3Power
If the sub includes a battery charger with capacitors and resistive fluid, then mechanical motion can be converted to electrical energy, but the device complexity increases
Solution Approach 1:
The battery charger is designed to perform multiple functions: converting rotational mechanical energy to electrical energy, converting vibrational mechanical energy to electrical energy, and charging the storage battery. The generator and triboelectric materials are integrated into a single device that handles various types of mechanical input, reducing the need for separate systems and managing the complexity through multi-functionality.
Solution Approach 2:
The triboelectric materials and resistive fluid act as intermediaries that convert mechanical energy from different sources (rotation and vibration) into electrical energy. These intermediary components facilitate the energy conversion process in a unified manner, managing the complexity by providing a common mechanism for handling multiple types of mechanical input.
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
Enhances battery capacity and power supply to downhole electronics by efficiently converting mechanical motion into electrical energy, addressing the challenges of limited space and extreme conditions.
Implementation Method 1
The bearing surfaces are comprised of different triboelectrically active materials that, when mated together, will generate an electrical charge in response to relative motion between the bearing surfaces
Data Source
AI summary
A sub for a pipe assembly and system and method for use of the same are disclosed. In one embodiment, the sub includes a mandrel having a body section including an internal flow passage that extends generally axially through the mandrel from an upper connection end to a lower connection end. A battery charger is located within a recessed region within the mandrel. Capacitors include opposing spaced plates having contact segments thereon. An output power increasing, electrically resistive fluid is held within and partially fills an enclosed chamber. In response to movement of the sub, induced relative motion between the output power increasing, electrically resistive fluid and contact segments varies the fluid-contact segment contact within the enclosed chamber, thereby generating an electrical charge. An electronic circuit, which is coupled to the opposing spaced plates, is configured to transfer the electrical charge to a battery associated with the mandrel.