Smooth Wireline Armor with Shaped Cross-Sections
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Solution Overview
Problem
Conventional wireline cables used for borehole logging face challenges in sealing due to voids created by their braided design, which limits the cable's outside diameter under pressure and increases friction and environmental concerns.
Innovation Solution
The design of wireline cables with shaped inner and outer armor wires provides a nearly smooth outer surface, allowing for a larger diameter with greater strength and reduced friction, while maintaining efficient sealing and pressure control through a helical pattern of armor wires that move independently to maintain cable shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional braided cable design is used, then cable flexibility and structural integrity are maintained, but voids are created that increase friction and reduce sealing efficiency
Solution Approach 1:
The patent changes the geometric parameters of the armor wires from conventional round cross-sections to specially shaped cross-sections (such as oval, flat, or other non-circular shapes). This parameter change eliminates voids between wires, creates a smooth outer surface, reduces friction with the seal, and improves sealing efficiency while maintaining cable flexibility and structural integrity.
2Strength
If cable outside diameter is increased for greater strength, then load bearing capacity improves, but voids increase leading to worse sealing and increased friction
Solution Approach 1:
The patent changes the cross-sectional shape parameters of the armor wires to eliminate voids. This allows the cable to be manufactured with a larger outside diameter for greater strength without proportionally increasing void space. The shaped wires pack more efficiently, maintaining a smooth outer surface that reduces friction and improves sealing even as the cable diameter and strength increase.
3Ease of manufacture
If conventional round armor wires are used, then manufacturing is simpler, but voids are created between wires reducing sealing efficiency
Solution Approach 1:
The patent modifies the cross-sectional shape parameter of the armor wires from circular to non-circular shapes. While this requires slightly more complex manufacturing processes, it eliminates voids between wires and creates a smooth outer surface that significantly improves sealing efficiency and reduces friction with the seal, thereby enhancing overall system reliability.
4Reliability
If grease is used to seal voids in conventional cables, then sealing is achieved, but environmental concerns and grease loss occur
Solution Approach 1:
The patent extracts and eliminates the source of the problem by removing voids from the cable structure through the use of shaped armor wires. By changing the wire cross-sectional shape to pack tightly together, the design eliminates the need for grease-filled voids, thereby achieving sealing without the environmental hazards and maintenance issues associated with grease loss.
Solution Approach 2:
The patent changes the geometric parameters of the armor wires to eliminate voids, creating a dense, void-free structure. This structural parameter change removes the need for grease-based sealing, eliminating environmental contamination risks while maintaining reliable sealing and pressure control.
Data Source
AI summary
A cable includes a conductor. A plurality of inner armor wires is wrapped around the conductor. At least some of the plurality of inner armor wires have non-circular and non-rectangular cross-sectional shapes. A plurality of outer armor wires are wrapped around the inner armor wires. At least some of the plurality of outer armor wires have non-circular and non-rectangular cross-sectional shapes.