Dual Alternator Roll Stabilized Control for Rotary Steerable Drilling
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Solution Overview
Problem
Rotary steerable drilling tools face challenges in achieving precise angular position control and efficient power management, particularly at higher drilling speeds, which affects steerability and rate of penetration.
Innovation Solution
A rotary controlled system employing first and second alternators connected via a DC voltage bus, with field-oriented controllers providing constant DC voltage and servo angular position control, respectively, to optimize the roll-stabilized housing's rotationally coupled components, enabling efficient motor and servo control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional power management and control systems are used in rotary steerable drilling tools, then the tool can operate, but precise angular position control and efficient power management are not achieved, especially at higher drilling speeds
Solution Approach 1:
The control system is segmented into two independent field-oriented controllers: first FOC controller dedicated to voltage regulation and second FOC controller dedicated to angular position control. This segmentation allows each controller to optimize its specific function independently, enabling precise angular position control while maintaining efficient power management at higher drilling speeds.
Solution Approach 2:
The system dynamically allocates power between the two alternators based on real-time operational demands. The first alternator dynamically regulates DC bus voltage while the second alternator dynamically adjusts angular position, allowing the system to adapt to varying drilling speeds and maintain optimal performance across different operating conditions.
2Productivity
If a single controller manages both power regulation and angular position control, then device complexity is reduced, but control precision and performance at higher speeds deteriorate
Solution Approach 1:
The control system is divided into two independent field-oriented controllers operating on the same DC bus. The first FOC controller manages voltage regulation from the first alternator, while the second FOC controller manages angular position control from the second alternator. This segmentation enables high-speed drilling performance without excessive complexity, as each controller handles a specific function efficiently.
Solution Approach 2:
Both alternators share the same DC bus and mechanical connection structure, providing a universal platform that serves dual functions: voltage regulation and angular position control. This multi-functionality approach achieves high productivity without proportionally increasing device complexity, as the shared infrastructure is utilized by both controllers.
3Reliability
If multiple alternators are used for improved control, then angular position control and power management improve, but electric power conversion losses increase
Solution Approach 1:
The field-oriented controllers implement closed-loop feedback control to optimize power conversion efficiency. By continuously monitoring and adjusting the electrical parameters of both alternators, the system minimizes power conversion losses while maintaining reliable operation. The feedback mechanism ensures that each alternator operates in its optimal efficiency range.
Solution Approach 2:
The system dynamically changes electrical parameters (voltage, current, frequency) of the two alternators based on operational demands. By optimizing these parameters in real-time, the system achieves reliable operation with minimized power conversion losses, adapting to different drilling conditions without excessive energy waste.
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 solution enhances angular position control, improves tool performance metrics like steerability and rate of penetration, and reduces electric power conversion within the tool, providing robust and efficient operation.
Implementation Method 1
first and second alternators electrically connected to one another via a DC voltage bus
Implementation Method 2
second field oriented controller is electrically connected with the second alternator and configured to receive electrical power from the voltage bus and cause the second alternator to provide servo angular position control
Data Source
AI summary
A rotary controlled system includes first and second alternators electrically connected to one another via a DC voltage bus. The alternators may optionally be further mechanically connected to one another via corresponding rotationally coupled components (such as rotationally coupled stators). A first field oriented controller is electrically connected with the first alternator and configured to cause the first alternator to provide a constant DC voltage to the voltage bus. A second field oriented controller is electrically connected with the second alternator and configured to receive electrical power from the voltage bus and cause the second alternator to provide servo angular position control of the rotationally coupled components. The system may be employed in a downhole rotary steerable tool to provide servo angular position control of a roll stabilized housing.