Modular Downhole Tool Connector With Suspension Unit
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Solution Overview
Problem
The existing connection systems for downhole tools in drilling operations face challenges due to difficulties in making reliable mechanical and electrical connections, especially under high pressure and temperature conditions, which can lead to tool failure and compromised operability.
Innovation Solution
A modular connector system that includes a suspension unit and electrical connectors, allowing for secure mechanical and electrical coupling between tools, with the suspension unit enabling movement of the electrical connector along the axial direction in response to applied force, ensuring stable connections despite environmental conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional threaded connections are used for downhole tools, then mechanical coupling between tools is achieved, but connection reliability deteriorates under high pressure and temperature conditions
Solution Approach 1:
The connection system is divided into separate mechanical connector and electrical connector components. The mechanical connector handles structural coupling while the electrical connector manages electrical connections independently, allowing each component to be optimized for its specific function and reducing the compounding effects of high pressure and temperature on a single integrated connection point.
Solution Approach 2:
A suspension unit acts as an intermediary between the mechanical connector and electrical connector, providing flexible coupling that accommodates thermal expansion and pressure-induced movements. This intermediary component absorbs environmental stresses before they reach the electrical connections, maintaining connection reliability under harsh downhole conditions.
2Reliability
If rigid electrical connectors are used in downhole tools, then electrical connections are established, but connection stability deteriorates when subjected to environmental forces
Solution Approach 1:
The electrical connector is designed with dynamic characteristics through the suspension unit, allowing it to move and adjust its position in response to applied forces from high pressure and temperature. This dynamic design maintains electrical contact stability by accommodating environmental forces rather than resisting them rigidly, preventing connection failure under downhole conditions.
3Reliability
If modular connector system with suspension unit is implemented, then connection stability under environmental forces is improved, but device complexity increases
Solution Approach 1:
By segmenting the connector system into distinct mechanical and electrical components connected through a suspension unit, the patent manages complexity through functional separation. Each component can be designed, manufactured, and maintained independently, reducing overall system complexity despite the addition of the suspension unit, while improving connection stability under environmental forces.
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 modular connector system provides reliable and stable electrical and mechanical connections between downhole tools, enhancing tool operability and reducing the risk of failure, even under high pressure and temperature conditions.
Implementation Method 1
The suspension unit is configured to permit the first electrical connector to move along the axial direction with respect to the first mechanical connector response to a force applied to the first electrical connector
Data Source
AI summary
An embodiment includes a downhole tool with first and second modular connectors. The connection modules are configured to aid make-up and assembly and improve stability during use.