Magnetic Coupling Actuator for Downhole Ball-Seat Wear Reduction
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Solution Overview
Problem
The actuation of ball-seat assemblies in downhole tools can cause wear and damage due to pressure waves generated by the impact between the ball and the ball seat, leading to potential damage and inefficiency in hydrocarbon exploration and recovery operations.
Innovation Solution
An actuator system that uses a magnetized ball and an electrically conductive conduit to generate eddy currents, creating a repulsive force that slows the ball's descent and reduces impact, allowing actuation without direct contact, utilizing magnetic coupling to impede the ball's motion and control its velocity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ball is released into a fluid conduit to actuate a ball-seat assembly, then the actuation function is achieved, but pressure waves are generated causing wear and damage to components
Solution Approach 1:
The patent replaces the direct mechanical impact system with an electromagnetic interaction system. A magnetized ball interacts with an electrically conductive ball receiving element to generate eddy currents, which create a magnetic repulsive force that actuates the ball-seat assembly without mechanical contact. This substitution eliminates pressure waves and component wear while maintaining actuation functionality.
Solution Approach 2:
The patent introduces an electromagnetic field as an intermediary between the ball and the ball-seat assembly. The magnetized ball generates a magnetic field that induces eddy currents in the conductive receiving element, creating a magnetic coupling that transmits actuation force without direct contact. This intermediary field enables force transmission while avoiding mechanical impact and pressure wave generation.
2Device complexity
If direct contact between ball and ball seat is used for actuation, then simple mechanism is achieved, but wear and damage occur
Solution Approach 1:
The patent replaces the simple direct-contact mechanical actuation system with an electromagnetic actuation system using a magnetized ball and conductive receiving element. Although the mechanism becomes slightly more complex, it eliminates wear and damage by avoiding direct contact, significantly improving component longevity and reliability.
Solution Approach 2:
The patent employs composite functionality by combining magnetic properties (in the ball) and electrical conductivity (in the receiving element) to create a non-contact actuation system. This composite approach uses different material properties working together to achieve actuation without mechanical contact, reducing wear while maintaining functional simplicity.
3Speed
If ball velocity is high during actuation, then quick response is achieved, but impact forces increase causing damage
Solution Approach 1:
The patent replaces mechanical impact-based actuation with electromagnetic interaction. The magnetized ball interacts with the conductive receiving element through eddy currents, generating a controlled magnetic repulsive force that actuates the assembly. This allows for quick response times without high-velocity impact, as the electromagnetic force can be generated instantaneously upon ball insertion.
Solution Approach 2:
The patent applies preliminary anti-action by generating eddy currents in the conductive receiving element as the magnetized ball approaches, creating a magnetic repulsive force that opposes the ball's motion before contact. This preliminary opposing force prevents high-velocity impact by gradually decelerating the ball and converting kinetic energy into electromagnetic interaction, thereby reducing impact forces while maintaining quick actuation response.
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
This solution significantly reduces pressure surges and wear on the ball-seat assembly, enabling the use of wider construction materials and simpler designs, while maintaining fluid flow during actuation by minimizing mechanical interaction and impact forces.
Implementation Method 1
one of the ball and the ball receiving element is configured to produce a magnetic field
Implementation Method 2
eddy currents are generated in the electrically conductive material
Implementation Method 3
the electrically conductive material is exposed to the magnetic field as the ball advances through the ball receiving element, and eddy currents are generated
Implementation Method 4
eddy currents are generated in the electrically conductive material that cause a repulsive force between the ball receiving element and the ball
Data Source
AI summary
An actuator includes: a carrier including an axially elongated fluid conduit therein, the fluid conduit configured to received a ball therein; and an axially elongated ball receiving element, wherein one of the ball and the ball receiving element is configured to produce a magnetic field, and another of the ball and the ball receiving element includes an electrically conductive material, the ball and the ball receiving element configured so that the electrically conductive material is exposed to the magnetic field as the ball advances through the ball receiving element, and eddy currents are generated in the electrically conductive material that cause a repulsive force between the ball receiving element and the ball to at least one of reduce a velocity of the ball and actuate the ball receiving element.