Reusable Battery Module for Downhole Drilling Tools
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Solution Overview
Problem
Drilling operations face financial losses and inefficiencies due to the need for frequent battery replacements in downhole tools, as existing battery management systems lack real-time monitoring and efficient power switching, leading to premature battery depletion and cessation of drilling.
Innovation Solution
A battery assembly with an integral memory unit and a removable module equipped with a processor and communications unit for monitoring and transmitting battery information, allowing for selective activation and switching between multiple batteries to ensure continuous power supply to downhole tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If multiple batteries are connected in parallel to power downhole tools, then the duration of power supply is extended, but the device complexity increases
Solution Approach 1:
The battery system is divided into multiple independent battery assemblies, each with its own intelligence components. This segmentation allows the system to extend operational duration by using multiple batteries while managing complexity through modular design, where each battery assembly can be independently monitored and controlled.
Solution Approach 2:
The intelligence components (processor, memory, communications unit) are designed to be universal and reusable across multiple battery assemblies. The module can be removed from one battery and attached to another, allowing the same intelligence components to serve multiple batteries, thus extending power supply duration without proportionally increasing system complexity.
2Reliability
If batteries are replaced frequently to maintain power supply, then the reliability of power supply is improved, but the loss of time increases
Solution Approach 1:
The processor continuously monitors battery capacity and charge levels through the memory unit and communicates this information to the surface via the communications unit. This feedback mechanism allows operators to track battery status in real-time and plan replacements strategically, maintaining reliable power supply while minimizing downtime by avoiding premature or delayed replacements.
Solution Approach 2:
The system enables preliminary monitoring and assessment of battery status before depletion occurs. By tracking capacity and charge levels in advance, operators can prepare for battery replacements proactively, scheduling them during optimal times rather than reacting to sudden power failures, thus maintaining reliability while reducing time loss.
3Measurement precision
If intelligence components are integrated into each battery, then the measurement precision of battery status is improved, but the device complexity increases
Solution Approach 1:
Instead of creating unique complex intelligence components for each battery, the system uses reusable modular modules that can be attached to different batteries. These modules contain the necessary processor, memory, and communications units that copy the same monitoring and communication functionality across multiple batteries, achieving precise measurement without proportionally increasing complexity.
Solution Approach 2:
The intelligence components are designed to be recoverable and reusable. When a battery is replaced, the intelligence module can be removed and attached to a new battery, discarding only the depleted battery while recovering the expensive intelligence components. This approach enables precise monitoring of multiple batteries without the complexity of permanently integrating unique intelligence systems into each battery.
Data Source
AI summary
A system, assembly, module, and method are disclosed for powering a downhole tool in a drilling operation. The system may include a reusable battery module and/or controller to operate multiple batteries.