Transformer-Based Switching System for Multi-Phase Current Control
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Solution Overview
Problem
Electrical devices, such as submersible pumps, face challenges in controlling multi-phase current in harsh environments due to limited mechanical switching solutions and high costs associated with extensive cabling, especially at great depths where repairing or replacing components is costly and time-consuming.
Innovation Solution
A switching system utilizing a transformer and switch cells with solid state switching devices, including diodes and gate drive circuits, to control current conduction along multiple power cables, reducing the need for multiple signal conductors and using passive components to operate reliably under high temperature and pressure conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple power cables or wires are installed to extend from the surface down the well to the ESP to separately deliver different phases of current, then multi-phase current can be supplied to the ESP, but the cost of cables or wires increases significantly
Solution Approach 1:
The patent makes the power cable serve multiple functions by enabling it to carry both power signals (multi-phase current) and control signals (activation control signals for switching devices) through the same cable. This is achieved by using the power cable's conductors for both power transmission and control signal transmission, eliminating the need for separate signal cables and reducing overall cable quantity and cost.
2Ease of operation
If additional signal cables or wires are used to provide drive signals for the ESP and control signals for electrical switches, then control functionality is improved, but the total cost of cables or wires increases
Solution Approach 1:
The power cable is designed to function as both a power transmission medium and a control signal transmission medium. The same cable conductors that carry multi-phase power current also carry activation control signals to the switching devices, thereby eliminating the need for separate signal cables and reducing total cable quantity and cost.
3Ease of operation
If mechanical switching solutions are used to control multi-phase current, then current conduction can be controlled, but the system becomes unreliable under harsh conditions of high temperature and pressure
Solution Approach 1:
The patent replaces mechanical switching devices with solid-state switching devices (such as IGBTs or MOSFETs) that have no moving parts. These solid-state devices are controlled by electrical activation control signals transmitted through the power cable, eliminating the reliability issues associated with mechanical components in harsh high-temperature and high-pressure environments while maintaining current conduction control capability.
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
The system effectively controls multi-phase current conduction with reduced signal conductors, enhancing reliability and scalability, and lowering costs by using passive components and minimizing the length of signal cables, thus addressing the challenges of harsh environments and high operational expenses.
Implementation Method 1
The transformer is configured to receive an activation control signal from the switch controller at the primary winding via the power cable and convey the activation control signal to the switch cell via the secondary winding
Implementation Method 2
The switch cells each include first and second solid state switching devices having respective diodes. The diode of the first solid state switching device is conductively coupled in an opposite direction to the diode of the second solid state switching device
Data Source
AI summary
A switching system includes a transformer and a switching assembly for controlling conduction of current from a power source to a first load along a power cable. The switching assembly includes a switch cell conductively coupled to the power cable. The transformer has a primary winding and a secondary winding. The secondary winding is conductively coupled to the switch cell. The primary winding is conductively coupled to a switch controller via the power cable. The transformer is configured to receive an activation control signal from the switch controller at the primary winding via the power cable and convey the activation control signal to the switch cell via the secondary winding. The switch cell is configured to activate and conduct the current from the power source to the first load along the power cable responsive to receiving the activation control signal from the switch controller.