High Pressure Electrical Connector With Segmented Collets
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Solution Overview
Problem
Conventional electrical connectors in oil and gas applications face issues with unintended disconnections due to thermal expansion and fluid intrusion, leading to open or short circuits under high pressures and temperatures.
Innovation Solution
A high-pressure electrical connection assembly featuring separate electrical collets and a sleeve, where the first collet is optimized for mechanical strength and the second collet for electrical conductivity, providing a robust and forgiving connection that requires significant force to disconnect, and a slotted downhole cable design to minimize relative movement of internal components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single electrical collet is used in conventional connectors, then the device complexity is reduced, but the reliability of electrical connection deteriorates under thermal expansion and high pressure conditions
Solution Approach 1:
The electrical connection is divided into two separate collets: a first collet that receives the electrical conductor and a second collet that receives the electrical pin. This segmentation allows each collet to be independently optimized for its specific function, improving overall connection reliability under thermal expansion and high pressure conditions while maintaining manageable device complexity through modular design
Solution Approach 2:
Each collet is designed with specific local properties: the first collet is optimized for receiving and securing the electrical conductor with appropriate mechanical characteristics, while the second collet is optimized for receiving and contacting the electrical pin with suitable electrical conductivity and mechanical strength. This local optimization ensures reliable electrical connection without requiring excessive overall complexity
2Stability of the object's composition
If conventional connectors are used in high pressure environments, then the ease of manufacture is maintained, but the stability of electrical connection deteriorates due to relative movement from thermal expansion
Solution Approach 1:
By separating the electrical connection into two distinct collets with specialized functions, the design achieves superior stability under thermal expansion and high pressure. Each collet can be manufactured and assembled independently, allowing for precise fitting and reduced relative movement between components, thereby maintaining connection stability without significantly increasing manufacturing complexity
Solution Approach 2:
The second collet acts as an intermediary element between the electrical pin and the housing, providing a stable interface that accommodates thermal expansion differences. This intermediary structure absorbs dimensional changes and maintains reliable electrical contact, enhancing connection stability while using standard manufacturing techniques
3Reliability
If conventional connectors are used, then the device complexity is low, but the resistance to fluid intrusion deteriorates due to unintended disconnections
Solution Approach 1:
The two-collet design creates separate sealed chambers for the electrical conductor and electrical pin, preventing fluid intrusion pathways that exist in conventional single-collet designs. Each collet can be independently sealed to the housing, providing redundant protection against fluid intrusion while maintaining a manageable structural complexity through modular construction
Solution Approach 2:
The second collet is designed to maintain constant contact with the electrical pin through pre-applied compression forces, creating a sealed interface that prevents fluid intrusion before pressure differentials can cause disconnection. This prior cushioning effect ensures reliable sealing under high pressure conditions without requiring complex active sealing mechanisms
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 significantly enhances the reliability and stability of electrical connections by reducing the effects of thermal expansion and pressure, requiring pounds of force for disconnection and maintaining contact during vibrations and high environmental pressures, thus preventing open or short circuits.
Implementation Method 1
a first electrical collet having a first recess in a first end to receive the electrical conductor and a second recess in a second end to receive the electrical pin, the first electrical collet being in electrical contact with the electrical pin; a second electrical collet to receive the electrical pin, the second electrical collet being separate from the first electrical collet and being in electrical contact with the electrical pin
Implementation Method 2
due to higher environmental pressure and the thermal expansion differences between various components of the connector assembly, there can be some relative movement between the connector components and the electrical cable components
Data Source
AI summary
Downhole connection assemblies include a connector to receive a conductor and pin at opposite ends. The connector includes a first electrical collet, a separate second electrical collet and a sleeve. The first collet includes a first recess in a first end to receive the conductor and a second recess in a second end to receive the pin. The second collet is positioned around the pin and separated from the first collet. The sleeve is positioned around the pin, first collet and the second collet. Downhole cables include a center electrical conductor, a first insulator positioned around the center conductor, a second insulator positioned around the first insulator, and a pressure tube surrounding the second insulator. The cable further includes one or more slots extending axially along a length of the second insulator, or one or more slots extending axially along an inner diameter of the pressure tube.