Hydrostatic Stroke Amplifier for Downhole Force Generator
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Solution Overview
Problem
Electro-mechanical downhole force generators typically have a limited stroke length and slower setting speed, which is insufficient for certain downhole tools requiring longer strokes and quicker setting times.
Innovation Solution
A hybrid downhole force generator combining hydrostatic pressure and electro-mechanical power, utilizing a stroke amplifier powered by hydrostatic pressure to provide a longer stroke and a DFG with a shorter, higher force stroke, connected via one-way slips to allow relative motion and efficient setting of wellbore sealing devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If electro-mechanical DFG is used, then setting force is sufficient, but stroke length is limited and setting speed is slow
Solution Approach 1:
The patent introduces a hydrostatic pressure actuated stroke amplifier that uses hydraulic pressure to extend the stroke length of the DFG. The stroke amplifier converts hydraulic pressure into mechanical motion, providing additional stroke length beyond what the electro-mechanical DFG can achieve alone, while maintaining sufficient setting force for wellbore sealing devices.
Solution Approach 2:
The patent combines two different actuation mechanisms - the electro-mechanical DFG and the hydrostatic pressure actuated stroke amplifier - into a hybrid system. The DFG provides high force for setting events, while the stroke amplifier provides extended stroke length, creating a complementary system that overcomes the limitations of either mechanism used alone.
2Force
If electro-mechanical DFG is used, then setting force is sufficient, but setting speed is slow
Solution Approach 1:
The hydrostatic pressure actuated stroke amplifier uses hydraulic pressure to achieve faster actuation speeds compared to the electro-mechanical DFG. The rapid pressure transmission in the hydraulic system enables quicker stroke execution, thereby increasing the overall setting speed while the DFG maintains the necessary force levels.
3Length of moving object
If stroke amplifier is added, then stroke length is extended, but device complexity increases
Solution Approach 1:
The stroke amplifier acts as an intermediary component between the hydraulic pressure source and the downhole tool setting mechanism. It translates hydraulic pressure into the mechanical stroke motion needed, providing a modular solution that extends stroke length without requiring complete redesign of the entire DFG system.
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 hybrid system enables faster and more efficient setting of wellbore sealing devices with a longer stroke length, reducing setting time and operational costs by leveraging hydrostatic pressure for low-force, long-stroke actions and electro-mechanical power for high-force events.
Implementation Method 1
a piston slidable within a housing and movable in response to hydrostatic pressure
Implementation Method 2
one-way slips which allow relative motion of the piston and shaft in one direction
Data Source
AI summary
Methods and apparatus are presented for a hybrid downhole force generator (DFG) using a stroke amplifier driven by hydrostatic pressure for a low-force, long-stroke portion of setting a downhole tool and a DFG powered shaft for a high-force, short-stroke portion of setting the tool. The stroke amplifier has a piston slidable in a housing, movable in response to hydrostatic pressure. The DFG powered shaft is connected to the piston via one-way slips which allow relative motion of the piston and shaft in one direction. The amplifier housing is connected to the DFG housing. In use, the DFG shaft is powered by a power supply, such as an electric motor, etc. The shaft is powered to shear a shearing mechanism, freeing the piston to move in response to the hydrostatic pressure.