Initiator Head Circuit Board for Wire-Safe Detonator Assembly
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Solution Overview
Problem
The assembly of perforating guns is prone to issues such as twisted and crimped electrical wires, manual connection errors, and safety risks due to physically wiring live explosives, while orientation of perforations is crucial for optimal hydraulic fracturing results.
Innovation Solution
An initiator head with a circuit board and terminals that allows for reliable detonation through electrical communication, eliminating manual wiring and ensuring orientation verification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual wiring of electrical wires is used during assembly, then the initiator can be connected to the detonating cord, but the wires become twisted, crimped, and damaged, leading to assembly errors and safety risks
Solution Approach 1:
The initiator is divided into separate modular components: a housing containing the detonating cord and initiator mechanism, and separate electrical wire connectors. This segmentation allows each component to be assembled independently without manual wire manipulation, eliminating wire damage while maintaining connectivity.
Solution Approach 2:
An intermediary connector mechanism is introduced between the electrical wire and the initiator. This connector serves as a mediator that receives the electrical signal without requiring direct manual wiring to the detonating cord, thus protecting wire integrity while ensuring reliable signal transmission.
2Ease of operation
If manual connection of electrical wires is performed, then the initiator can be wired to the detonating cord, but safety risks increase due to physically wiring live explosives
Solution Approach 1:
The hazardous function of manually connecting live explosives is extracted and separated from the assembly process. The initiator housing pre-encapsulates the detonating cord and explosive mechanism, allowing operators to connect pre-assembled safe modules rather than manually wiring live explosives, thus eliminating safety risks while maintaining operational simplicity.
Solution Approach 2:
The dangerous wiring operation is performed in advance during manufacturing when the initiator is assembled in a controlled environment. The electrical connections are pre-established and sealed within the housing before the initiator reaches the field, so that end-users only need to connect safe external interfaces, eliminating safety risks during operational wiring.
3Ease of manufacture
If threaded insertion of components is used during assembly, then the initiator parts can be joined together, but the rotating assembly causes wires to become torn, twisted, and crimped
Solution Approach 1:
The assembly is segmented into rigid structural components that can be threaded together, while electrical connections are made through separate connector interfaces that remain stationary during assembly. This segmentation allows mechanical assembly operations without subjecting wires to rotational stresses, maintaining wire integrity while enabling easy assembly.
Solution Approach 2:
Electrical connections are transitioned from a linear wiring path subjected to rotational stress to a three-dimensional connector interface where wires enter through sealed openings. This dimensional change allows the wire connection point to remain stationary while other components are assembled around it, preventing wire damage during threaded insertion operations.
Data Source
AI summary
An initiator head may include a housing extending in an axial direction and a circuit board provided in an interior space of the housing. A thickness direction of the circuit board may be substantially parallel with the axial direction. The initiator head may further include a line-in terminal provided on a first side of the housing in the axial direction and accessible from an exterior of the housing. The line-in terminal may be in electrical communication with the circuit board.