Downhole Electronics Carrier with Insulating Flow Tube

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Solution Overview

Problem

Downhole probes in drilling operations face harsh conditions such as high temperatures, vibrations, and high pressures, leading to shortened lifespan and increased failure rates, which in turn increase the cost of replacing these probes and hinder efficient drilling operations due to unreliable telemetry data.

Innovation Solution

A downhole electronics system with a housing and drilling fluid flow tube that supports electronic components, providing mechanical protection and sealing against drilling fluid ingress, and includes EM telemetry capabilities using an electrically insulating flow tube to prevent electrical shorts and enhance data transmission reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If downhole probes are used to transmit telemetry data, then drilling efficiency is improved through real-time data transmission, but the probes fail more frequently due to harsh downhole conditions

Engineering Contradiction:

Improvedrilling efficiencyVSAvoidprobe reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The probe is divided into modular electronic components (telemetry module, power module, sensor module) that can be independently replaced. The housing is segmented with removable end caps allowing access to internal components without replacing the entire probe assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The probe incorporates a resilient support structure with flexible mounting for electronic components, allowing the probe to dynamically respond to vibrations and shocks. The drilling fluid flow tube provides dynamic cooling as fluid flows through the probe during operation.

Inventive Principle:

Principle #15Dynamics

2Temperature

If drilling fluid flows through the probe housing, then cooling of electronic components is achieved, but electrical shorts may occur without proper insulation

Engineering Contradiction:

Improveelectronic component temperatureVSAvoidelectrical connection reliability

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

An electrically insulating flow tube is introduced as an intermediary between the drilling fluid and electronic components. This mediator allows thermal energy transfer for cooling while preventing electrical conduction that would cause shorts.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The insulating flow tube acts as a flexible protective shell that conforms to the internal geometry of the probe housing while maintaining electrical isolation. The thin-walled tube provides adequate insulation without excessive bulk.

Inventive Principle:

Principle #30Flexible shells and thin films

3Extent of automation

If electronic components are mounted inside the probe housing, then telemetry functionality is achieved, but the components are vulnerable to vibrations and shocks

Engineering Contradiction:

Improvetelemetry functionalityVSAvoidcomponent durability

Core Design Contradiction:

Extent of automationVSReliability

Solution Approach 1:

Electronic components are mounted on a resilient support structure that provides beforehand cushioning against vibrations and shocks. The support structure includes compliant mounting features that absorb mechanical energy before it reaches sensitive components.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The probe housing creates a protected environment for electronic components, isolating them from the harsh external downhole conditions including drilling fluid, high pressure, and mechanical stress.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

4Reliability

If the probe housing is sealed to prevent fluid ingress, then electronic components are protected, but manufacturing and assembly become more difficult

Engineering Contradiction:

Improveelectronic component protectionVSAvoidassembly ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The housing is segmented into modular sections with standardized interfaces, allowing sealed assemblies to be manufactured separately and then easily joined. This modular approach maintains sealing integrity while simplifying manufacturing and assembly processes.

Inventive Principle:

Principle #1Segmentation

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 system effectively protects electronic components from harsh downhole conditions and ensures reliable data transmission through EM telemetry, reducing the likelihood of probe failure and enhancing drilling efficiency by maintaining the integrity of the drilling fluid flow and preventing electrical interference.

Implementation Method 1

use of an electrically insulating flow tube to prevent electrical shorts

Methodology Applied

Scientific EffectElectrical insulation: Electrical Resistance

Implementation Method 2

transmitting information by way of electromagnetic signals that propagate at least in part through the earth (EM telemetry)

Methodology Applied

Scientific EffectElectromagnetic signal transmission: Electromagnetic Induction

Data Source

PatentUS10352151B2Downhole electronics carrier

Publication Date: 2019.07.16 EVOLUTION ENG

AI summary

A drill string section receives an electronics package. A flow channel extends through an aperture in the electronics package. The flow channel carries a flow of drilling fluid through the drill string section. The flow channel is sealed to a body of the drill string section. The electronics package need not be pressure-rated.