Downhole Tool Variable Speed Control via Hydraulic Feedback
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Solution Overview
Problem
Existing downhole self-propelling wireline tools are limited in their ability to maintain constant speed over long distances and efficiently utilize power, as they can only be adjusted at the surface to drive at a single speed, leading to wasted power in areas where less force is needed and compromised velocity due to excessive friction.
Innovation Solution
A downhole self-propelling wireline tool equipped with a controllable valve system that adjusts fluid pressure based on real-time measurements, allowing for optimal power usage and friction control, enabling variable speed and efficient propulsion by using a feedback loop between pressure sensors and electric control units to manage the rotational speed of electric and hydraulic motors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the driving unit is adjusted at surface to drive at a predetermined speed, then the speed can be maintained constant, but the power available in the well is not fully utilized and velocity is compromised due to excessive friction
Solution Approach 1:
The driving unit incorporates a variable speed drive system that allows continuous adjustment of rotational speed based on real-time feedback from pressure sensors monitoring fluid pressure. This enables the system to adapt dynamically between maintaining constant speed and maximizing velocity, resolving the contradiction between speed consistency and productivity
Solution Approach 2:
Pressure sensors continuously monitor fluid pressure in the hydraulic system and feed this information back to the control unit. The control unit adjusts the driving unit's speed accordingly, optimizing performance by preventing excessive friction while maintaining speed when needed, thus resolving the contradiction between speed consistency and velocity
2Force
If the first fluid pressure is increased to propel the tool forward, then the propulsion force increases, but power is wasted and friction increases compromising maximum velocity
Solution Approach 1:
The system uses variable speed control of the electric motor driving the hydraulic pump, allowing the first fluid pressure to be dynamically adjusted to match actual propulsion needs. This prevents energy waste by avoiding excessive pressure while maintaining sufficient propulsion force
Solution Approach 2:
The control unit modifies operational parameters (motor speed, pump flow rate, fluid pressure) based on feedback from pressure sensors to optimize the balance between propulsion force and energy consumption, resolving the contradiction between force generation and energy loss
3Speed
If the driving unit has multiple driving sections, then higher speed can be achieved by activating only one section, but the device complexity increases and requires driving at two different speeds
Solution Approach 1:
Instead of using multiple discrete driving sections that require switching between different speeds, the invention implements a single driving section with variable speed capability. This allows the system to achieve different speeds continuously without structural complexity or operational switching
Solution Approach 2:
The single driving unit is designed to perform multiple functions (maintaining constant speed, achieving maximum velocity, adapting to varying power availability) through variable speed control, eliminating the need for multiple specialized driving sections and simplifying the overall device structure
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
The tool can maintain maximum speed while ensuring sufficient power is used efficiently, reducing wear and preventing shutdowns by optimizing fluid pressure and friction, thus overcoming the limitations of prior art in power utilization and speed consistency.
Implementation Method 1
an electric motor operating at a rotational speed and powered by a wireline
Implementation Method 2
a first hydraulic pump driven by the electric motor for generation of a second fluid pressure of a second fluid for driving the hydraulic motor(s) rotating the wheel(s)
Implementation Method 3
each wheel comprising a hydraulic motor for rotation of the wheel to provide a self-propelling movement
Implementation Method 4
a plurality of projectable arm assemblies movably connected at a first arm end with the tool body and projectable from the tool body by means of a first fluid having a first fluid pressure
Implementation Method 5
each wheel being connected with a second arm end of one of the arm assemblies
Data Source
AI summary
A downhole driving unit for propelling a tool forward in a well and/or for providing weight on a bit while performing an operation, includes a tool body, an electric motor powered by a wireline, a plurality of projectable arm assemblies connected in a first arm end with the tool body, a plurality of wheels for contacting a wall of the well, each wheel comprising a hydraulic motor for rotation of the wheel, each arm assembly being at a second arm end connected with one of the plurality of wheels, and a first hydraulic pump driven by the electric motor for generation of a first fluid pressure for projection of the plurality of projectable arm assemblies. The downhole driving unit further comprises a hydraulic section with a first controllable valve controlling the first fluid pressure.