Helical Control Line Connector Tangential Alignment
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Solution Overview
Problem
Conventional fiber optic connectors for downhole applications in the oil and gas industry face issues with debris accumulation and fiber buckling due to axial alignment and compression, leading to connection failures and data loss.
Innovation Solution
A control line connector assembly that uses tangential or curvilinear alignment and rotation of connection housings to establish connections, incorporating a retractable cover and penetrable lid to prevent debris entry and maintaining optical fibers in low stress compression to prevent buckling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If axial alignment and compression are used in conventional fiber optic connectors, then connection establishment is achieved, but debris accumulation on mating faces and fiber buckling occur
Solution Approach 1:
The patent inverts the conventional axial alignment approach by using tangential alignment where the fiber ends are aligned perpendicular to the axis of compression. The mating faces are brought together tangentially rather than axially, which prevents debris accumulation on the mating surfaces while still achieving reliable optical connection. This inversion of the alignment direction resolves the contradiction between connection reliability and debris accumulation.
Solution Approach 2:
The patent transitions from one-dimensional axial alignment to a combination of tangential alignment and rotational movement. The fiber connection is established by bringing mating faces together in a tangential direction followed by rotation, effectively adding a rotational dimension to the connection process. This dimensional change allows the fiber to avoid column loading and buckling while maintaining connection integrity.
2Reliability
If telescoping metal housing is used to align and wash fiber faces, then optical communication is established, but the structure becomes complex and prone to soiling
Solution Approach 1:
The patent extracts and eliminates the complex telescoping metal housing mechanism from the connector design. Instead of using nested male and female housings that telescope together, the invention employs a simplified structure where fiber ends are directly aligned and brought into contact through tangential movement and rotation. This extraction of the complex housing system reduces structural complexity while maintaining optical communication capability.
Solution Approach 2:
The patent changes the alignment parameter from axial to tangential, and introduces rotational movement as a new parameter for connection establishment. Instead of relying on the complex telescoping mechanism to provide alignment and washing functions, the invention uses tangential alignment combined with rotation to achieve the same objectives with a simpler structure.
3Ease of operation
If axial compression is applied to connect fiber housings, then mating faces contact, but inner housing moves inside outer housing creating buckling risk
Solution Approach 1:
The patent inverts the compression direction from axial to tangential. Instead of compressing the fiber along its length which causes buckling, the fiber ends are brought together tangentially and then rotated into final contact. This inversion of the connection mechanism eliminates column loading on the fiber while maintaining ease of operation.
Solution Approach 2:
The patent introduces dynamic rotational movement as the final step in the connection process. Rather than static axial compression, the fiber connection is dynamically established through rotation after tangential alignment. This dynamic approach allows the fiber to maintain structural integrity while achieving reliable mating between connectors.
Data Source
AI summary
Systems including wellbore tubing having an anchor assembly, an upper control line connector coupled to the anchor assembly, a first housing, and a first connector. The first connector provides a first angular mating face that faces tangentially with respect to the first housing, an upper control line operatively coupled to the first housing, and first communication media that extend through the first housing to the first angular mating face. A completion assembly within a wellbore has a completion receptacle to receive the anchor assembly, a lower control line connector coupled to the completion receptacle and a second housing and a second connector. The second connector provides a second angular mating face that faces tangentially with respect to the second housing, and a lower control line operatively coupled to the second housing and one or more second communication media that extend through the second housing to the second angular mating face.