Failsafe High Torque Drive for Downhole Anchor Release
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Solution Overview
Problem
Existing high torque transmission drives in well intervention operations face challenges such as being stuck downhole due to power failures, large volumetric envelopes, and inability to scale for varying torque requirements and size constraints.
Innovation Solution
A downhole apparatus with a failsafe high torque electromechanical transmission drive that includes a motor, input gearbox, clutch, and output gearbox with a lower gear ratio, allowing automatic release of anchors upon power de-energization and reduced size for smaller diameters, enabling scalable torque applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a high torque transmission drive is used, then high torque can be transmitted to set the anchor, but the volumetric envelope becomes too large for some downhole applications
Solution Approach 1:
The transmission drive is segmented into two gearbox stages with different gear ratios. The first gearbox provides high gear reduction for high torque requirements, while the second gearbox provides additional reduction with a smaller size. This segmentation allows the system to achieve the required torque transmission capability while keeping the overall volumetric envelope smaller than a single-stage drive would require.
2Force
If a high torque transmission drive is used, then anchor deployment is possible, but the drive is not scalable to meet varying torque requirements and size constraints
Solution Approach 1:
The two-stage gearbox configuration allows independent optimization of each stage for different torque requirements. By segmenting the transmission into multiple stages with different gear ratios, the system can be scaled and adapted to meet varying torque demands and size constraints of different downhole applications.
Solution Approach 2:
The clutch mechanism provides dynamic adaptability by enabling the system to switch between engaged and disengaged states. This dynamic capability allows the same drive configuration to adapt to different operational requirements, enhancing versatility across various torque and size scenarios.
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 apparatus ensures the tool string is not stuck in the wellbore during power failures, reduces the physical size of components, and allows for high torque applications in constrained spaces, making it suitable for various downhole operations.
Implementation Method 1
a motor extending within the first housing and driving an input gearbox
Implementation Method 2
an input gearbox having a first gear ratio... an output gearbox optionally coupled to the first clutch so that the output gearbox is driven by the input gearbox
Data Source
AI summary
According to one aspect, a downhole apparatus includes an anchor element mechanically coupled between first and second housings and linked to move radially between first and second radial positions; and a high torque electromechanical transmission drive; wherein the anchor element is adapted to engage a preexisting structure when the downhole apparatus extends within the preexisting structure, the high torque electromechanical transmission drive is energized, and the anchor element is in the second radial position; and wherein the high torque electromechanical transmission drive is failsafe in that the anchor element is permitted to move radially from the second radial position towards the first radial position in response to de-energization of the high torque electromechanical transmission drive. In several embodiments, the preexisting structure is a casing positioned within a wellbore that traverses a subterranean formation.