Segmented Open-Core Transformer for Downhole Pulse Generation
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Solution Overview
Problem
Downhole electrocrushing drilling systems face challenges in efficiently generating high-energy electrical pulses to fracture rock formations due to the harsh environment and mechanical stress, which affects the reliability and efficiency of the pulse-generating circuit.
Innovation Solution
The implementation of an open-core, multi-segmented transformer pulse-generating circuit that steps up low-voltage input to high-voltage output, capable of withstanding extreme temperatures and mechanical shock, is used to generate high-energy electrical pulses for downhole electrocrushing drilling, allowing for efficient rock fracturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional pulse-generating circuit is used in downhole electrocrushing drilling, then the circuit can generate electrical pulses to fracture rock, but the circuit reliability deteriorates due to harsh environment and mechanical stress
Solution Approach 1:
The transformer is divided into multiple segments with each winding separated into discrete sections. These segmented windings are arranged in a modular configuration around the core, allowing the circuit to withstand mechanical stress and thermal expansion without compromising overall reliability. The segmentation enables independent replacement and reduces stress concentration.
Solution Approach 2:
The pulse-generating circuit incorporates dynamic elements including switchable capacitor banks and controllable rectifier bridges that can adapt their configuration based on operating conditions. This dynamic adaptability allows the circuit to maintain reliability across varying downhole environments by optimizing performance parameters in real-time.
2Power
If voltage is stepped up from low-voltage input to high-voltage output, then high-energy electrical pulses can be generated for rock fracturing, but the device complexity increases
Solution Approach 1:
The transformer circuit serves multiple functions simultaneously: it steps up voltage, provides electrical isolation, and acts as an energy storage element through its magnetic core. The same circuit components that enable voltage transformation also provide overvoltage protection and energy buffering, reducing the need for separate protective devices and simplifying the overall system.
Solution Approach 2:
The circuit employs a nested configuration where capacitor banks are positioned within the transformer structure, and rectifier elements are integrated into the same housing. This nesting arrangement consolidates multiple high-voltage components into a compact unified structure, reducing overall device complexity while maintaining high-power output capability.
3Adaptability or versatility
If the circuit operates in harsh downhole conditions with extreme temperatures, then drilling can proceed in various geological formations, but the circuit efficiency deteriorates
Solution Approach 1:
The circuit incorporates temperature-compensated components with characteristics that change predictably with temperature. Capacitor values and transformer winding resistances are selected to maintain optimal performance across the expected temperature range. The control system adjusts operating parameters such as pulse frequency and duty cycle based on temperature sensors, maintaining circuit efficiency despite thermal variations in different geological formations.
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
This solution enables the reliable and efficient generation of high-energy pulses for rock fracturing, improving the drilling process by maintaining circuit efficiency and reliability in harsh downhole conditions, thereby enhancing drilling performance and efficiency.
Implementation Method 1
a transformer circuit electrically coupled to the input stage circuit, the transformer circuit comprising an open-core transformer configured to generate an output voltage higher than the input voltage
Data Source
AI summary
A downhole drilling system is disclosed. The downhole drilling system may include a pulse-generating circuit electrically coupled to a power source configured to provide an alternating current at a frequency and an input voltage, the pulse-generating circuit comprising an input stage circuit electrically coupled to the power source, the input stage circuit configured to control the alternating current in the pulse-generating circuit; a transformer circuit electrically coupled to the input stage circuit, the transformer circuit comprising an open-core transformer configured to generate an output voltage higher than the input voltage; and an output stage circuit electrically coupled to the transformer circuit, the output stage circuit configured to store energy for an electric pulse; and a drill bit including a first electrode and a second electrode electrically coupled to the output stage circuit to receive the electric pulse from the pulse-generating circuit.