Non-Ballistic Force Generating Mechanism for Downhole Actuation
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Solution Overview
Problem
Existing resource exploration and recovery systems face challenges in applying high energy forces to downhole operations without relying on ballistic actuators, which require rapid thermal expansion and can be complex and hazardous.
Innovation Solution
A non-ballistic force generating mechanism comprising a first actuator delivering a constant pressure over a long stroke length and a second actuator producing a significantly higher pressure over a shorter stroke length, utilizing an electromagnetic launcher and thermally responsive expandable materials to achieve high energy actuation without ballistic components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a ballistic actuator is used to provide high energy force, then the force output is improved, but the device complexity and safety hazards increase
Solution Approach 1:
The actuation system is divided into two separate actuators: a first actuator that provides initial movement and a second actuator that delivers the high-energy force. This segmentation allows each component to be optimized for its specific function, reducing the complexity that would arise from a single complex ballistic mechanism.
Solution Approach 2:
The first actuator serves as an intermediary mechanism that prepares the system for the second actuator's high-energy operation. By using this intermediate step, the system achieves high force output without requiring a single complex ballistic actuator, thereby reducing overall device complexity and safety hazards.
2Force
If a ballistic actuator is used to provide high energy force, then the force output is improved, but the safety risks increase
Solution Approach 1:
By segmenting the actuation into two separate non-ballistic actuators, the system eliminates the safety hazards associated with ballistic materials and rapid thermal expansion while still achieving the required high force output through coordinated operation of the two actuators.
Solution Approach 2:
The invention converts the potentially harmful ballistic mechanism into a beneficial two-stage non-ballistic system. The first actuator's lower-pressure operation prepares the system safely, while the second actuator delivers the necessary high force without the hazards of ballistic expansion, effectively turning a harmful approach into a safe solution.
3Device complexity
If pressure from the surface is used to manipulate the element, then the system simplicity is improved, but the force capability is insufficient
Solution Approach 1:
The system uses two distinct actuators with different force profiles: the first actuator provides initial movement with lower pressure, and the second actuator delivers high-energy force with substantially greater pressure. This segmentation enables the system to achieve high force capability while maintaining relative simplicity by using two straightforward actuation stages rather than a complex single-stage system.
Solution Approach 2:
The first actuator performs preliminary action by moving the element to an intermediate position and preparing the system for the second actuator's high-force operation. This preliminary step enables the second actuator to deliver its maximum force effectively, achieving high force capability while keeping the overall system relatively simple.
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
Enables efficient and controlled high-energy actuation of downhole devices, such as slip assemblies, without the need for ballistic materials, reducing complexity and safety risks, and allowing for a wide range of downhole operations like packer setting and valve operation.
Implementation Method 1
a non-ballistic first actuator operable to output a first force profile defining a first pressure for a first stroke length
Implementation Method 2
a non-ballistic second actuator operable to output a second force profile following the first force profile, the second force profile defining an second pressure that is substantially greater than the first pressure for a second stroke length
Data Source
AI summary
A non-ballistic force generating mechanism includes a non-ballistic first actuator operable to output a first force profile defining a first pressure for a first stroke length, and a non-ballistic second actuator operable to output a second force profile following the first force profile, the second force profile defining an second pressure that is substantially greater than the first pressure for a second stroke length that is less than the first stroke length.