Modular Actuator for Downhole Tools via Impulse Generation
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Solution Overview
Problem
The resource recovery and fluid sequestration industries face challenges in standardizing actuators due to their unique dimensions and properties, leading to inefficiencies and the need for custom-designed actuators for each tool.
Innovation Solution
The development of a modular actuator system incorporating an impulse generation arrangement with an atmospheric pressure chamber, a valve, a prime mover arrangement, and a hydrostatic pressure source, connected via a hydraulic chamber, allowing for both negative and positive pressure actuation and adaptable to various tools through modular design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If actuators are custom-designed for each tool to address unique dimensions and properties, then the actuation performance for each specific tool is optimized, but the device complexity and manufacturing costs increase due to the need for multiple unique actuator designs
Solution Approach 1:
The patent applies universality by designing a single actuator architecture that can serve multiple tool types. The actuator uses standardized components including a universal housing, common hydraulic chamber, and interchangeable end effectors that adapt to different tool dimensions and properties, allowing one actuator design to perform multiple functions across various tools without requiring custom designs for each application
Solution Approach 2:
The actuator is segmented into modular components including a reusable main body, interchangeable end effectors, and separable mounting interfaces. This segmentation allows the core actuator mechanism to remain standardized while only the end effector portions need to be customized for different tools, reducing overall design complexity while maintaining adaptability
2Ease of manufacture
If custom actuators are designed for each tool, then the actuation is tailored to specific tool requirements, but the manufacturing efficiency and production costs decrease due to lack of standardization
Solution Approach 1:
The actuator design incorporates universal mounting interfaces and standardized hydraulic connections that allow the same actuator body to be manufactured once and then adapted to multiple tool types through interchangeable end effectors, significantly improving manufacturing efficiency while maintaining tool-specific actuation capabilities
Solution Approach 2:
The actuator employs adjustable and reconfigurable components including interchangeable end effectors and adjustable mounting brackets that can be dynamically configured for different tool requirements, allowing a single manufactured actuator body to adapt to various applications without requiring custom manufacturing for each tool type
3Productivity
If traditional actuators are integrated as part of each tool, then the mechanical energy transfer is optimized for that specific tool, but the ability to standardize components is reduced and industry efficiency is limited
Solution Approach 1:
The actuator design enables component standardization by using a universal actuator body that can be paired with different end effectors for various tools, improving industry productivity through reduced manufacturing complexity and inventory requirements while maintaining the ability to optimize mechanical energy transfer for each specific tool application through the interchangeable end effector interface
Solution Approach 2:
The invention merges the standardized actuator body with tool-specific end effectors into a unified actuation system. The universal actuator housing and hydraulic chamber are combined with interchangeable end effectors that attach to different tools, creating a standardized core component that can be efficiently produced and then adapted to multiple applications, thereby improving overall industry efficiency
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 enables a single actuator to be used across multiple tools, reducing the number of unique actuators required and enhancing efficiency by allowing for standardized components and adaptable actuation mechanisms.
Implementation Method 1
causing a low pressure pulse in the actuator, and moving the device piston with the pulse
Implementation Method 2
a hydraulic chamber disposed between and fluidically connecting the impulse generation arrangement and the prime mover arrangement
Data Source
AI summary
An actuator including an impulse generation arrangement including an atmospheric pressure chamber, and a valve connected fluidly to the chamber, a prime mover arrangement including a device piston, and a hydrostatic pressure source, and a hydraulic chamber disposed between and fluidically connecting the impulse generation arrangement and the prime mover arrangement. A method for actuating a downhole tool including signaling the trigger in an actuator, opening the atmospheric chamber of the actuator, causing a low pressure pulse in the actuator, and moving the device piston with the pulse. A borehole system including a borehole in a subsurface formation, a string in the borehole, and the actuator disposed within or as a part of the string.