Torque-balanced wireline cable with reversed armor layers
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Solution Overview
Problem
Wireline cables used in oilfield operations face issues with torque imbalance between armor wire layers, leading to cable stretch, deformation, and increased risk of corrosion and explosion hazards due to pressurized gas infiltration.
Innovation Solution
Incorporating soft polymer layers between the inner and outer armor wire layers and reversing the size configuration to place larger armor wires in the inner layer, which reduces torque imbalance and prevents gas infiltration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If larger-diameter armor wires are placed in the outer layer to provide protection against impact, cut through, and abrasion damage, then protection against mechanical damage is improved, but torque imbalance between armor wire layers increases
Solution Approach 1:
The patent inverts the conventional armor wire size arrangement by placing larger-diameter armor wires in the inner layer instead of the outer layer. This reversal resolves the torque imbalance problem caused by having larger wires on the outside, while still providing adequate protection through the outer layer wires and the bonded polymer structure.
Solution Approach 2:
The patent uses a composite structure where armor wires are bonded together and to the cable core through a polymer material. This composite approach allows the different sized wires to work together as a unified structure, distributing loads more evenly and eliminating the torque imbalance that would occur with traditional layered armor configurations.
2Force
If outer armor wires are made larger to carry the majority of the load, then load-bearing capacity is improved, but cable core deformation and inner armor wire tightness increase
Solution Approach 1:
The polymer bonding material creates a composite structure where all armor wires (both inner and outer) are mechanically coupled to the cable core and to each other. This allows the load to be distributed across all armor wires rather than concentrated in the outer layer, preventing cable core deformation and maintaining proper inner armor wire configuration.
Solution Approach 2:
The patent merges the inner and outer armor wire layers into a unified structural system through the polymer bonding material. This integration ensures that both layers work together to bear loads, preventing the outer wires from carrying disproportionate loads that would cause core deformation and inner wire tightening.
3Stability of the object's composition
If armor wire layers are applied counterhelically to minimize torque imbalance, then torque balance is improved, but gaps between armor wires remain allowing gas infiltration
Solution Approach 1:
The patent introduces a polymer bonding material as an intermediary substance that fills the gaps between counterhelically applied armor wire layers. This mediator maintains the torque-balancing counterhelical arrangement while simultaneously blocking the infiltration pathways that would otherwise allow gas to penetrate through the armor layers.
Solution Approach 2:
The combination of counterhelical armor wires bonded with polymer material creates a composite structure that achieves both torque balance and gas sealing. The polymer fills interstitial spaces while the counterhelical wire arrangement provides structural stability and torque equilibrium.
Data Source
AI summary
A smooth torque balanced cable that includes an electrically conductive cable core for transmitting electrical power. The smooth torque balanced cable also has a first polymer surrounding said cable core. An inner layer of a plurality of first armor wires surrounds the cable core. The first armor wires being in partial contact with the first polymer and partial contact with a second polymer disposed opposite the first polymer.