Multi-Contact Connector Assembly with Moveable Piston Seals
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Solution Overview
Problem
Existing electrical connectors in well drilling systems face challenges in maintaining reliable connections amidst harsh rig environments, including exposure to moisture, dust, and drilling mud, which can lead to faulty connections and equipment damage.
Innovation Solution
A multi-contact electrical connector assembly featuring moveable pistons and annular seals within cylindrical housings, providing both pressure barriers and electrical connections between drill collars, with mechanisms to ensure secure engagement and disengagement of contacts, even in wet conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrical connectors are used in harsh drilling environments, then the device complexity remains low, but the reliability of electrical connections deteriorates due to moisture, dust, and drilling mud contamination
Solution Approach 1:
The connector assembly is divided into separate functional components: a first connector housing with moveable piston for one set of electrical contacts, and a second connector housing with annular piston for another set of electrical contacts. Each housing can be independently assembled and tested, allowing complex functionality to be achieved through modular design while maintaining reliability in harsh environments.
Solution Approach 2:
The moveable piston and annular piston are disposed within bores of their respective connector housings, with one housing movable into the other housing during engagement. This nested arrangement protects the electrical contacts and sealing mechanisms within the hollow cavities of the pistons, shielding them from moisture, dust, and drilling mud while maintaining connection reliability.
2Object-affected harmful factors
If moveable pistons with annular seals are used to provide pressure barriers, then the resistance to environmental contaminants improves, but the device complexity increases due to additional sealing mechanisms
Solution Approach 1:
Annular seals are disposed on the outer surfaces of the moveable piston and within the second connector housing bore, forming flexible sealing barriers that conform to the cylindrical interfaces. These thin film seals effectively block moisture, dust, and drilling mud from reaching the electrical contacts while adding minimal structural complexity to the overall assembly.
Solution Approach 2:
The moveable piston and annular piston act as intermediary elements between the electrical contacts and the harsh external environment. These pistons with integrated seals create a protective interface that transmits mechanical engagement forces while blocking contaminant ingress, thereby protecting the electrical connections without requiring direct exposure to the external environment.
3Adaptability or versatility
If multiple electrical contacts are exposed for mating engagement, then the electrical connection capability improves, but the difficulty of detecting and measuring proper engagement increases
Solution Approach 1:
Multiple electrical contacts are merged into two distinct sets: one set on the moveable piston within the first connector housing, and another set on the annular piston within the second connector housing. This consolidation of multiple contacts into organized arrays on rotating surfaces enables comprehensive electrical connectivity while the rotational engagement mechanism provides a single detectable motion indicator that all contacts are properly mated.
Solution Approach 2:
The engagement detection mechanism utilizes the rotational motion and potential vibration characteristics of the moveable piston and annular piston during make-up. As the threaded connections are tightened and the pistons rotate into engagement, the electrical contacts make sequential contact, creating detectable mechanical signals that confirm proper mating of all electrical connections without requiring individual inspection of each contact.
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 solution ensures reliable and durable electrical connections between drill collars, resisting environmental contaminants and maintaining operational integrity, thus enhancing drilling operations by preventing faulty connections and equipment damage.
Implementation Method 1
A biasing member is disposed in the bore of the first connector housing between a terminal end of the bore in the first connector housing and the moveable piston
Implementation Method 2
Sealing engagement between the annular seal of the moveable piston and the first connector housing bore forms a sealed chamber between the annular seal and the terminal end of the first connector housing bore
Implementation Method 3
The first pressure connector on the first connector housing is to releasably provide both a pressure barrier between the bore of the first connector housing and a bore of a first tubular member
Data Source
AI summary
A multi-contact electrical connector assembly includes a first connector housing to electrically couple to a second connector housing. A moveable piston is disposed in a bore of the first housing and is biased to be adjacent a first plurality of electrical contacts on a surface of the bore. An end of the first housing has a first pressure connector electrically coupled to the first plurality of electrical contacts. A moveable annular piston is disposed about a rod in a bore of the second connector housing and is biased to isolate a second plurality of electrical contacts on an outer surface of the rod. The second housing also has a pressure connector electrically coupled to the second plurality of electrical contacts. The moveable piston and the moveable annular piston are simultaneously moveable to expose and matingly engage the electrical contacts.