Composite Cable Rope Socket for Uniform Armor Wire Load Distribution
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Solution Overview
Problem
The existing methods for connecting wireline tool strings to surface equipment are time-consuming and prone to mechanical and electrical failures due to uneven loading of armored layers.
Innovation Solution
An apparatus comprising a rope socket coupled with an armored cable, where the armored cable has a conductor core for signal transmission and layers of armor wires, and the rope socket has a housing with spacers to space the armor wires from the conductor core, filled with a plastic material to enhance mechanical and electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional rope socket assemblies are used to connect wireline tool strings, then mechanical and electrical connections can be established, but the connections are prone to failure due to uneven loading of armored layers and the process is time-consuming
Solution Approach 1:
The armored cable is pre-assembled with the conductor core and armor wires in proper configuration before insertion into the rope socket housing. The armor wires are pre-positioned and spaced apart from the conductor core, and plastic material is pre-injected to fill interstices, creating a pre-integrated assembly that reduces on-site connection time while ensuring uniform load distribution and reliable connections
2Strength
If armor wires are tightly wound around the conductor core in traditional assemblies, then mechanical strength is provided, but uneven loading occurs leading to connection failures
Solution Approach 1:
The armor wires are positioned with specific local spacing characteristics - they are spaced apart at least locally from the conductor core in certain regions while maintaining protective coverage. This non-uniform local positioning prevents stress concentration and uneven loading on the conductor core, distributing mechanical loads more evenly across the assembly while maintaining overall mechanical strength and connection reliability
3Reliability
If plastic material is injected to fill interstices between armor wires and conductor core, then uniform contact and load distribution are achieved, but manufacturing complexity increases
Solution Approach 1:
The plastic material is injected into the housing using injection molding or similar injection-based processes. This method automatically fills the interstices between armor wires and conductor core in a controlled manner, achieving uniform contact and load distribution. The injection process is integrated into the assembly operation, adding minimal complexity while ensuring consistent and reliable load distribution across the connection
Data Source
AI summary
Apparatus and methods for coupling a rope socket with an armored cable. The armored cable includes a conductor core having one or more cables for transmitting electrical and/or optical signals and at least one layer of armor wires wound around the conductor core. The rope socket includes a housing having an uphole end through which the armored cable extends into the housing and a downhole end through which the conductor core extends from the housing to a component of downhole equipment suspended in a wellbore by the armored cable. The armor wires are arranged inside of the housing so that they are spaced apart at least locally from the conductor core. A plastic material disposed within the housing fills interstices each defined by one or more surfaces of one or more of the conductor core, one or more of the armor wires, and the housing.