Sensor Adapter for Downhole Milling Tool
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Solution Overview
Problem
There is a need for apparatus and methods to install a sensor in a downhole tool, particularly in a milling tool used for forming lateral wellbores off a parent wellbore.
Innovation Solution
The solution involves integrating a sensor adapter and sensor assembly into the milling tool. The sensor adapter is connected to the tubular body of the milling tool, and the sensor assembly, which includes one or more sensors and a carrier, is attached to the adapter shaft. This configuration allows for accurate measurement of geophysical parameters such as orientation, gravity, velocity, and acceleration during the milling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is integrated into a downhole milling tool, then measurement precision of geophysical parameters is improved, but device complexity increases
Solution Approach 1:
The sensor integration system is divided into separate functional modules: a sensor adapter assembly that couples to the milling tool, and a sensor assembly that contains the actual sensing elements. This segmentation allows the sensor system to be added as a modular component without redesigning the entire milling tool, thereby improving measurement precision while controlling device complexity through standardized interfaces and separate functional blocks.
Solution Approach 2:
A sensor adapter serves as an intermediary component between the milling tool and the sensor assembly. The adapter includes a receiver that couples to the milling tool and a shaft that extends to receive the sensor assembly, creating a standardized interface that simplifies integration. This intermediary structure allows precise sensor installation without directly complicating the milling tool's core milling function.
2Reliability
If a sensor adapter and sensor assembly are integrated into the milling tool, then reliability of geophysical parameter measurement is improved, but device complexity increases
Solution Approach 1:
The sensor assembly is nested within the sensor adapter, which itself couples to the milling tool. The sensor assembly includes a carrier that receives the sensor, and this nested configuration ensures proper positioning and protection of the sensor elements. The nested structure maintains reliability by securing the sensor in a stable, protected environment while minimizing the increase in overall device complexity through efficient space utilization.
Solution Approach 2:
The sensor adapter is pre-configured with a receiver and shaft structure that facilitates easy coupling to the milling tool and secure mounting of the sensor assembly. This preliminary preparation of the adapter structure ensures reliable sensor installation and positioning before the actual measurement operation, reducing the likelihood of measurement errors or sensor failure during drilling.
3Productivity
If sensors are installed in the milling tool to monitor geophysical parameters, then productivity of drilling operations is improved through better decision-making, but device complexity increases
Solution Approach 1:
The sensor adapter and sensor assembly are designed with universal applicability to various milling tool configurations. The adapter's receiver and shaft interface can accommodate different sensor types and milling tool variants, allowing the same integration structure to serve multiple measurement functions. This multi-functionality improves productivity by enabling comprehensive monitoring of multiple geophysical parameters (orientation, gravity, velocity, acceleration) without requiring separate specialized components for each parameter type.
Data Source
AI summary
A downhole assembly includes a tubular body having a bore and a downhole tool connected to the tubular body. The downhole assembly also includes a sensor assembly having a carrier and a sensor. A sensor adapter is used to couple the sensor assembly to the tubular body. The sensor adapter includes an adapter body disposed in the bore of the tubular body; an adapter shaft for connection with the carrier; and a plurality of channels formed between the adapter shaft and the adapter body.