Power Controller Series Parallel Switching Drilling RPM
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Solution Overview
Problem
In subsurface wellbore drilling, the varying fluid flow rates cause generator rotational speed fluctuations, leading to a wide range of RPM variations that are not effectively managed by conventional power supplies, resulting in undesirable power interruptions when switching relays are used to adjust generator output.
Innovation Solution
A power controller system that dynamically connects multiple generators in series or parallel using a voltage-measuring and control circuit to maintain a stable output voltage across a wide range of RPMs, allowing for seamless switching without interrupting power delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If relay switching is used to change generator output connections to adapt to RPM variations, then the generator can operate across different RPM ranges, but power interruptions occur during switching
Solution Approach 1:
The patent uses dynamic switching elements (transistors or thyristors) that can change state rapidly under control circuit guidance, allowing the generator to transition between series and parallel connections without mechanical relay interruptions. The dynamic control circuit monitors voltage and current continuously and switches configurations seamlessly based on real-time conditions.
Solution Approach 2:
The control circuit receives feedback signals from voltage and current sensors monitoring the generator output. Based on this feedback, the control circuit determines the appropriate connection configuration (series or parallel) and activates the switching elements accordingly, ensuring continuous power delivery while adapting to RPM variations.
2Device complexity
If a single generator is used to cover a wide RPM range, then device complexity is reduced, but the generator cannot maintain stable output voltage across varying fluid flow rates
Solution Approach 1:
The patent employs a single generator with dynamically reconfigurable electrical connections. By changing the connection topology (series or parallel) of the generator windings through electronically controlled switching elements, the system maintains stable output voltage across a wide RPM range without requiring multiple physical generators.
3Stability of the object's composition
If multiple generators are used to maintain stable output voltage, then voltage stability is improved, but device complexity and the need for frequent generator changes increase
Solution Approach 1:
The patent divides a single generator into multiple independent winding sections that can be connected in series or parallel configurations. This segmentation allows the generator to provide stable output voltage across varying RPM ranges while using only one physical generator unit, reducing complexity compared to using multiple separate generators.
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 generators to operate over a broader RPM range while maintaining a consistent power output, reducing the need for frequent generator changes and minimizing power interruptions, thus enhancing the reliability of electrically operated drilling tools.
Implementation Method 1
A circuit for measuring voltage and for control is coupled to the positive and negative output terminals of the first power supply and a second power supply. The circuit for measuring voltage and for control may close the main switching element when a measured voltage exceeds a selected threshold
Implementation Method 2
a first pair of diodes is serially connected across the electrical load
Data Source
AI summary
A power controller includes at least a first and a second power supply each having a positive and a negative output terminal. A voltage measuring circuit is coupled to the positive and negative output terminals of at least one of the power supplies. A main switching element is coupled between the negative output terminal of the first power supply and the positive output terminal of the second power supply. The positive output terminal of the first power supply and the negative output terminal of the second power supply are connected to an electrical load. A pair of diodes is serially connected across the electrical load. The voltage measuring circuit is configured to close the main switching element when a measured voltage exceeds a selected threshold such that the first power supply and the second power supply are connected to the electrical load in parallel when the main switching element is closed.