Halbach Magnetic Tool with Composite Wiper
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Solution Overview
Problem
Conventional magnetic circuits fail to effectively capture and remove fine ferrous metal particulate from oilfield drilling mud streams, as it passes through shale shaker screens, leading to re-introduction into the wellbore and inefficiencies in recycling processes.
Innovation Solution
A magnetic tool with a Halbach magnetic circuit and end plates, combined with a composite, multi-component wiper that allows ferrous metal to be safely and efficiently removed from the magnetic bar by urging it through an open architecture, using non-ferrous materials and fasteners like nylon-insert flange locknuts for secure attachment without the need for additional bolts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional magnetic circuit is used, then the structure is simple, but it fails to effectively capture fine ferrous metal particulate
Solution Approach 1:
The magnetic circuit is segmented into multiple magnetic bars arranged in a Halbach array configuration, where each bar contributes to the overall magnetic field in a specific orientation. This segmentation allows the system to achieve superior magnetic field distribution and capture effectiveness for fine ferrous metal particulate while maintaining manageable structural complexity through modular assembly.
2Ease of operation
If end plates are permanently affixed to the magnetic bar, then the structure is stable, but the wiper cannot be easily removed for cleaning
Solution Approach 1:
The wiper assembly incorporates a dynamic attachment mechanism using C-clamps that can be quickly adjusted and secured to the magnetic bar. This allows the wiper to be firmly attached during operation for stable performance, yet easily removed when cleaning is needed, providing operational flexibility without compromising structural stability during use.
3Productivity
If a composite multi-component wiper is used, then the cleaning effectiveness is improved, but the device complexity increases
Solution Approach 1:
The wiper is constructed as a composite multi-component assembly including a C-clamp mechanism, positioning block, and flexible wiping element. This composite structure integrates multiple functions (attachment, positioning, and wiping) into a single removable unit, improving cleaning effectiveness while managing complexity through functional integration of components that can be manufactured and replaced independently.
4Ease of repair
If the wiper is designed to be removable without end plates, then the maintenance is easier, but the structural integrity is compromised
Solution Approach 1:
The wiper assembly is extracted as a separate removable component from the main magnetic bar structure, attached via C-clamps that engage with features on the magnetic bar. This extraction allows the wiper to be easily removed for cleaning and replacement without affecting the end plates or the core magnetic bar, maintaining structural integrity while enabling straightforward maintenance.
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 magnetic tool enhances ferrous metal capture and cleaning efficiency, reducing safety hazards and time required for cleaning cycles, allowing for quicker re-use of the ditch magnet by effectively removing captured metal through the wiper mechanism.
Implementation Method 1
A Halbach magnetic circuit or array provides increased attracting and holding power over conventional magnetic circuits. The Halbach array effectively increases the magnetic surface gauss which, in turn, holds more ferrous metal
Implementation Method 2
It is highly important to capture ferrous metal in the drilling mud stream
Data Source
AI summary
A magnetic tool may be provided with a ditch magnet that may include end plates (or handles) having a mostly open architecture, and these end plates may be permanently affixed to the ends of the magnetic bar. Ferrous metal may pass through by urging captured ferrous metal from one end of the ditch magnet to the opposite end. The captured ferrous metal may be urged from one end of the ditch magnet bar to an opposite end using a composite, multi-component wiper. The wiper may remove captured ferrous metal safely and effectively from the ditch magnet bar.