Electric Push-Pull Tool Using Planetary Roller Screw for Downhole Thrust
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Solution Overview
Problem
Existing setting tools for oil and gas wells, particularly those using explosives and hydraulics, pose safety hazards, have limited driving force, are environmentally sensitive, require frequent maintenance, and are not suitable for all wellbore conditions.
Innovation Solution
An electric heavy-load push-pull tool with a power input unit, power conversion unit, and power output unit, utilizing multiple stages of planetary reducers and a planetary roller screw to generate high-torque thrust and pulling forces, ensuring safety and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If explosive setting tools are used to generate thrust force, then the driving force can be achieved, but safety hazards arise during transportation, storage, and operation due to explosives being controlled substances
Solution Approach 1:
The patent replaces the explosive-based mechanical system with an electric motor-driven system. The motor (101) connects through a coupling (110) to a multi-stage planetary reducer (200), which drives a planetary roller screw (300) to generate thrust. This substitution eliminates explosives entirely, removing safety hazards while maintaining the ability to generate required thrust forces for bridge plug and packer setting operations.
Solution Approach 2:
The patent changes the fundamental operating parameter from chemical energy (explosives) to electrical energy (motor). The motor receives electrical power and converts it to mechanical rotation, which is then transformed into linear thrust through the planetary roller screw mechanism. This parameter change eliminates the safety issues associated with explosives while providing controlled, reliable force generation.
2Force
If powder setting tools are used to provide thrust, then the driving force is generated, but the energy efficiency is greatly reduced when powder gets damp due to environmental factors
Solution Approach 1:
The patent replaces the powder-based combustion system with an electric motor system. The motor (101) converts electrical energy directly to mechanical rotation with high efficiency, avoiding the energy losses associated with powder combustion. The multi-stage planetary reducer (200) and planetary roller screw (300) efficiently transmit and convert this rotational energy to linear thrust, maintaining high energy efficiency regardless of environmental conditions.
Solution Approach 2:
The electric motor system is self-regulating and not affected by environmental factors like moisture. The motor receives electrical power and automatically converts it to mechanical work with consistent efficiency, unlike powder which degrades when damp. The system requires no special storage conditions or environmental controls, providing reliable energy conversion in all downhole conditions.
3Force
If powder setting tools are used to generate driving force, then thrust is produced, but the maximum thrust is limited to 24 tons which is insufficient for special circumstances like casing patches
Solution Approach 1:
The patent employs a multi-stage planetary reducer (200) with five stages that can dynamically adjust the torque multiplication ratio. By changing the gear configuration and using a planetary roller screw (300) with adjustable lead, the system can adapt to different thrust requirements. The motor (101) can vary its rotational speed and torque output, enabling the system to generate thrust forces exceeding 24 tons for special circumstances like casing patches while maintaining versatility for standard applications.
Solution Approach 2:
The electric motor-driven system with multi-stage planetary reduction and planetary roller screw provides universal adaptability. The system can generate a wide range of thrust forces by adjusting motor parameters and reducer ratios, making it suitable for both standard bridge plug/packer setting operations and special circumstances like casing patches, sleeve cutting, and bridge perforating integration, replacing multiple specialized tools with one versatile system.
4Loss of energy
If pressure relief port is configured in powder setting tool for releasing gas when raised from wellhead, then gas can be discharged, but hidden dangers arise including pre-setting of bridge plug/packer and high-pressure gas injury accidents
Solution Approach 1:
The patent replaces the powder combustion system that generates high-pressure gas with an electric motor system that produces no gas. The motor (101) converts electrical energy to mechanical work directly, with no combustion byproducts. The planetary reducer (200) and planetary roller screw (300) transmit this mechanical energy without generating gas pressure, completely eliminating the need for pressure relief ports and the associated safety hazards of pre-setting and gas injury accidents.
Solution Approach 2:
The patent eliminates the harmful byproduct (high-pressure gas) at its source by replacing the combustion process with an electric motor system. Instead of managing the harm through pressure relief ports, the design prevents gas generation entirely, converting a potentially dangerous system into a safe one that requires no special gas discharge procedures and eliminates the risk of accidental activation.
5Ease of operation
If powder setting tool is used, then setting function is achieved, but maintenance cycle is short requiring maintenance after each use which is laborious
Solution Approach 1:
The patent replaces the powder-based system with an electric motor system that has no consumable materials requiring replacement. The motor (101), planetary reducer (200), and planetary roller screw (300) are durable mechanical components designed for repeated use without degradation. This substitution eliminates the need for maintenance after each use, as there are no powder residues, combustion byproducts, or depleted energy sources that would require cleaning or replacement, significantly reducing maintenance time and labor.
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 tool provides high-torque thrust and pulling forces, enhances operational range, improves maintenance cycles, and ensures stability under seismic conditions, reducing maintenance frequency and costs.
Implementation Method 1
utilizing multiple stages of planetary reducers and a planetary roller screw to generate high-torque thrust and pulling forces
Implementation Method 2
The reducer is provided with multiple stages of planetary reducers: each of the multiple stages of planetary reducers includes a sun gear, a planetary plate, a planetary carrier and a plurality of planetary gears
Data Source
AI summary
Provided is an electric heavy-load push-pull tool including a power input unit, a power conversion unit and a power output unit. Through the transmission design of multiple stages of reducers and a planetary roller screw of a downhole operation tool, low-speed and high-torque power output of the motor is realized. The heavy-load push-pull tool provided by the present disclosure can not only provide large-torque thrust force, but also provide large-torque pulling force. A forward direction of a transmission nut is based on a rotation direction of a motor. By controlling the forward rotation or reverse rotation of a transmission shaft of the motor, the forward or backward movement of an operation tool can be realized at low cost through power transmission.