Steering Tool System Signal Separation and Full Bore Design
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Solution Overview
Problem
Existing steering tool systems for directional drilling face complications due to complex electronic arrangements, bore pathway issues, and unreliable conductor connections, leading to interference between downhole communication and motor control signals.
Innovation Solution
A steering tool system with an improved electronic schematic that separates downhole communication and sensor signals from motor control signals, using a dedicated Data Line for communication and orienter control, and featuring a full bore cablehead design for hydraulic disconnect and orienter control sections, which reduces the risk of electronic failures and allows for reliable orientation and rotation of the Bottom Hole Assembly (BHA).
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If downhole communication and sensor signals are combined with motor control signals in the same conductor, then device complexity is reduced, but reliability deteriorates due to interference between low-power and high-power signals
Solution Approach 1:
The patent segments the conductor into separate dedicated lines: a Data Line for low-power communication and sensor signals, and Power Lines for high-power motor control signals. This physical separation prevents signal interference while maintaining manageable system complexity through organized wiring architecture.
Solution Approach 2:
The patent introduces an intermediary filtering mechanism at the connector interface between cablehead sections. Filters are placed on the Data Line to block high-power motor control signals from interfering with low-power communication signals, allowing both signal types to coexist in the same electrical pathway when necessary.
2Ease of manufacture
If traditional cablehead connectors are used, then ease of manufacture is maintained, but reliability deteriorates due to unreliable conductor connections and electronic failures
Solution Approach 1:
The patent replaces traditional mechanical connector systems with a streamlined connector design that integrates filtering functionality directly into the connector structure. This eliminates complex mechanical assembly steps while improving reliability through built-in signal protection mechanisms.
3Device complexity
If bore pathway is blocked by traditional cablehead design, then device complexity is reduced, but productivity deteriorates due to inability to pump ball to hydraulic disconnect
Solution Approach 1:
The patent implements a dynamic full-bore cablehead design where the central passage remains open and unobstructed during normal operation. The connector components are positioned to allow free flow of drilling fluid and ball materials through the central bore, enabling hydraulic disconnect operations without requiring disassembly or complex pathway navigation.
Data Source
AI summary
A steering tool system may provide a bottom hole assembly (BHA) and a surface control/interface (SCI). The steering tool may provide an improved electronic schematic that provides a data line that is separate from the power line. The BHA may provide a full bore flow path. The connectors of a cablehead section may be designed to ease make up with proper contact to the connectors. The BHA may also be suitable for pumping a ball to a hydraulic disconnect. The design of the system allows conductors to pass through the hydraulic disconnect and orienter control section.