Grooved Brass Contact Pin for Bulkhead Shear Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current bulkhead assemblies used in perforating gun assemblies for hydrocarbon recovery operations are costly due to the need for expensive, heavy metal materials and lack sufficient shear strength and reliable electrical connections, particularly in high-pressure and high-temperature downhole environments.
Innovation Solution
A bulkhead assembly fabricated from non-conductive materials like plastic or nylon, with an electrically conductive contact pin and interlocking grooves for increased shear strength, and a tandem sub design that enhances electrical connections and signal transmission within the perforating gun assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If expensive, heavy metal materials are used for bulkhead assemblies, then strength and reliability are improved, but material cost and weight increase
Solution Approach 1:
The bulkhead assembly uses a composite structure combining non-conductive plastic or nylon material with electrically conductive contact pins. This composite approach provides the necessary mechanical strength and environmental durability while reducing overall weight compared to fully metal constructions, and allows for cost-effective material selection.
Solution Approach 2:
The bulkhead body is made from non-conductive plastic or nylon providing structural strength, while the contact pin is locally made from electrically conductive material only where electrical transmission is required. This localized application of conductive material reduces overall weight and cost while maintaining necessary electrical functionality.
2Weight of moving object
If non-conductive materials are used for bulkhead assemblies, then material cost and weight are reduced, but electrical connection reliability deteriorates
Solution Approach 1:
The bulkhead assembly combines non-conductive plastic or nylon material for the bulkhead body with electrically conductive contact pins. This composite structure provides both the weight and cost benefits of non-conductive materials and the reliable electrical connection benefits of conductive materials, where each material is used only where its properties are most beneficial.
Solution Approach 2:
The contact pin acts as an intermediary element that bridges the non-conductive bulkhead body and the electrical signal transmission requirements. The contact pin provides the necessary electrical conductivity while being mechanically integrated into the non-conductive bulkhead structure, allowing reliable signal transmission without requiring the entire bulkhead to be conductive.
3Ease of manufacture
If conventional bulkhead designs are used, then manufacturing simplicity is maintained, but shear strength and connection reliability are insufficient
Solution Approach 1:
The bulkhead assembly is segmented into distinct functional components: the bulkhead body made from non-conductive plastic or nylon, and separate contact pins made from electrically conductive material. This segmentation allows each component to be manufactured independently using optimized processes, then assembled together to achieve both ease of manufacture and high shear strength through precise interface design.
Solution Approach 2:
The composite construction of the bulkhead assembly allows the bulkhead body and contact pins to be manufactured from different materials optimized for their specific functions. The non-conductive plastic or nylon provides structural integrity and environmental resistance, while the conductive contact pins provide electrical transmission, achieving high shear strength without complicating the overall manufacturing process.
Data Source
AI summary
A bulkhead assembly for transmitting current to a downhole tool such as a perforating gun. The bulkhead assembly comprises a tubular bulkhead body having a bore therein. The bulkhead assembly also includes an electrical contact pin. The contact pin comprises a shaft having a first end and a second end. The shaft is fabricated substantially from brass and comprises a plurality of grooves. At the same time, the bore comprises a profile for mating with and receiving the plurality of grooves. This grooved, mating arrangement increases shear strength of the bulkhead assembly. Preferably, a first end of the electrical contact pin is in electrical communication with a wire within a wellbore. The wire transmits electrical signals from an operator at the surface. The shaft comprises a conical portion proximate the first end that frictionally fits into a mating conical profile of the bore. A tandem sub having an improved electrical communication is also provided herein.