Inflatable Downhole Actuator Axial Contraction

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Solution Overview

Problem

The hydrocarbon recovery industry faces challenges with complex, expensive, and heavy actuators for downhole tools like bridge plugs, which have multiple modes of failure and require simpler alternatives.

Innovation Solution

A downhole tool actuator utilizing an inflatable member with a radially expanding and axially contracting design, where the inflatable member is attached to both ends of the tool structures, allowing relative movement upon inflation to actuate the tool, eliminating the need for complex mechanisms and channels.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If complex mechanisms are used to actuate downhole tools, then the actuator can control multiple functions, but the device becomes larger, heavier, and more expensive with multiple modes of failure

Engineering Contradiction:

Improvecontrol of multiple functionsVSAvoidcomplex mechanisms

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The inflatable member serves multiple functions simultaneously: it acts as both the actuating mechanism and the seal. By inflating the member, the system achieves both mechanical actuation of the bridge plug and sealing of the wellbore, eliminating the need for separate complex mechanisms for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines the actuator and seal into a single integrated inflatable member. This merging of functions reduces the overall device complexity, weight, and number of potential failure modes while maintaining the ability to perform both actuation and sealing operations.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of operation

If traditional actuators are used for downhole tools, then the tool can be actuated, but the actuator is large and heavy

Engineering Contradiction:

Improvetool actuation capabilityVSAvoidactuator weight

Core Design Contradiction:

Ease of operationVSWeight of moving object

Solution Approach 1:

The inflatable member is constructed as a flexible membrane or thin-walled structure that can be inflated with fluid to generate the necessary actuating force. This flexible shell approach replaces heavy rigid mechanical actuators with a lightweight inflatable structure that achieves the same functional result through pressure differential rather than mass.

Inventive Principle:

Principle #30Flexible shells and thin films

3Adaptability or versatility

If complex actuators with multiple components are used, then the actuator can perform required functions, but the reliability decreases due to multiple modes of failure

Engineering Contradiction:

Improvefunctional capabilityVSAvoidfailure risk

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent extracts and eliminates unnecessary intermediate components from the actuation system. By using a direct inflatable member that transitions from a relaxed state to an inflated state, the system removes multiple potential failure points associated with complex mechanical linkages, gears, or hydraulic systems while maintaining the required functional capability.

Inventive Principle:

Principle #2Taking out (Extraction)

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 actuator provides a simpler, more reliable, and cost-effective means of actuating downhole tools by using an inflatable member that radially expands while axially contracting, reducing the risk of failure and allowing for precise control over the actuation sequence, including the setting of anchors without requiring additional channels or ports.

Implementation Method 1

an inflatable member, a first portion on an uphole end of the inflatable member that is attachable to a first structure of a downhole tool, and a second portion on a downhole end of the inflatable member that is attachable to a second structure of the downhole tool. The actuator configured so that the second structure is movable relative to the first structure in response to movement of the second portion relative to the first portion in response to inflation of the inflatable member.

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS8365835B2Method and downhole tool actuator

Publication Date: 2013.02.05 BAKER HUGHES CO

AI summary

A downhole tool actuator includes, an inflatable member, a first portion on an uphole end of the inflatable member that is attachable to a first structure of a downhole tool, and a second portion on a downhole end of the inflatable member that is attachable to a second structure of the downhole tool. The actuator configured so that the second structure is movable relative to the first structure in response to movement of the second portion relative to the first portion in response to inflation of the inflatable member.