Grooved Contact Pin Bulkhead Assembly for Tandem Sub
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Solution Overview
Problem
Current bulkhead assemblies used in hydrocarbon recovery operations for connecting perforating guns and transmitting detonation signals are prone to unreliable electrical connections due to soldered leads and require manual handling, which is time-consuming and error-prone, and are often made from expensive heavy metals, necessitating a more cost-effective and robust design.
Innovation Solution
A bulkhead assembly comprising a tubular body made from non-conductive materials like plastic or nylon, with an electrically conductive contact pin and interlocking grooves for increased shear strength, and an improved tandem sub with a conductive contact pin and communication system for reliable electrical connections, reducing assembly complexity and material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldered leads are used in bulkhead assemblies, then electrical connections can be made, but reliability deteriorates due to connection failures
Solution Approach 1:
The patent replaces the mechanical soldering process with a direct mechanical insertion system. The contact pin is inserted through the bulkhead body and secured with a retention mechanism, eliminating the need for soldering operations. This substitution improves reliability by removing the weak solder joint while maintaining ease of manufacture through simple insertion and retention.
Solution Approach 2:
The patent extracts the soldering step from the assembly process entirely. By using a contact pin with retention mechanism, the design removes the complex soldering operation and replaces it with a simpler mechanical insertion and securing process, thereby improving both reliability and ease of manufacture.
2Strength
If heavy metal materials are used for bulkhead assemblies, then strength is improved, but cost increases
Solution Approach 1:
The patent employs a composite construction where the bulkhead body is made from lightweight non-conductive material (such as polymer) and the contact pin is made from electrically conductive material (such as metal). This composite approach provides the necessary mechanical strength and electrical conductivity without requiring the entire bulkhead assembly to be made from expensive heavy metal, thereby reducing material cost while maintaining performance.
Solution Approach 2:
The patent applies local quality by using different materials for different functional requirements. The bulkhead body uses lightweight non-conductive material for structural integrity and insulation, while the contact pin uses conductive material for electrical function. This localized material selection optimizes both strength and cost effectiveness.
3Manufacturing precision
If manual handling is required for assembly, then precision can be maintained, but productivity decreases due to time consumption
Solution Approach 1:
The contact pin design incorporates self-aligning features and a retention mechanism that automatically secures the pin in place during assembly. This self-service capability maintains assembly precision through proper positioning and securing without requiring complex manual handling procedures, thereby improving productivity while preserving manufacturing precision.
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 solution provides a reliable, efficient, and cost-effective electrical connection system for perforating gun assemblies, enhancing shear strength and reducing assembly time and errors, while using less expensive materials without compromising performance in high-pressure and high-temperature environments.
Implementation Method 1
The contact pin is fabricated from an electrically conductive material for transmitting current from the first end to the second end
Implementation Method 2
The shaft comprises a plurality of grooves... The grooves of the electrical contact pin frictionally fit into the mating profile of the bulkhead body
Implementation Method 3
The conical portion frictionally fits into a mating conical profile of the receptacle
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 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 fits into a mating conical profile of the bore. A tandem sub having an improved electrical communication is also provided.