Transformer-Driven Solid-State Switching for Multi-Phase Current Control
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Solution Overview
Problem
Electrical devices, such as subterranean pumps, face challenges in controlling multi-phase current due to harsh conditions like high temperatures and pressures, leading to limited mechanical switching solutions and increased costs from lengthy power cables.
Innovation Solution
A switching system with multiple sets of solid state switch cells and a transformer, using passive components like diodes, capacitors, and transformers to control conduction of multiple phases of current, reducing the need for multiple signal conductors and enhancing reliability under high-temperature conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical switching solutions are used to control multi-phase current, then the system can operate under harsh conditions, but the available options are limited and reliability decreases
Solution Approach 1:
The patent replaces mechanical switching solutions with solid-state switching devices (such as IGBTs and MOSFETs) that have no moving parts. This substitution eliminates the limitations of mechanical switches in harsh environments while providing superior reliability and more versatile control options for multi-phase current management in ESP applications.
Solution Approach 2:
The patent changes the operating parameters of switching devices by using solid-state components rated for high temperatures (operating up to 200°C or higher) and high voltages. This allows the system to maintain reliability under harsh downhole conditions while enabling more flexible control strategies compared to mechanical alternatives.
2Reliability
If multiple power cables are installed to deliver different phases of current to ESPs at significant depths, then current conduction is achieved, but the cost increases significantly (approximately 40% or more of total operating cost)
Solution Approach 1:
The patent merges multiple power phases into a single three-phase power delivery system using a compact switching assembly that can handle all phases locally at the ESP. This consolidation reduces the need for multiple separate cable runs and minimizes the total cable length required, directly addressing the cost issue while maintaining reliable current delivery to deep-well ESPs.
Solution Approach 2:
The patent introduces a local switching assembly dimension between the surface power source and the ESP, allowing phase conversion and redistribution to occur in-situ. This dimensional addition enables more efficient cable utilization by converting between different phase configurations, thereby reducing the total cable length needed compared to traditional direct multi-phase cable delivery.
3Ease of operation
If additional signal cables are used to provide drive signals and control signals for electrical switches, then control functionality is achieved, but the overall system complexity and cost increase
Solution Approach 1:
The patent merges control signal delivery with the existing three-phase power cables by using one phase of the three-phase power system to carry control signals to the switching assembly. This integration eliminates the need for separate dedicated control signal cables, reducing system complexity while maintaining full control functionality for the solid-state switching devices.
4Reliability
If solid state switching devices are used instead of mechanical switches, then reliability under high temperature conditions improves, but the device complexity increases
Solution Approach 1:
The patent segments the switching function into modular solid-state switching cells, each handling a specific phase or function. This modular segmentation allows for easier management and control of the overall system complexity while maintaining the reliability benefits of solid-state devices under high-temperature conditions. Each module can be independently controlled and replaced if needed.
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, lowering costs and improving reliability in harsh environments, while maintaining operation under high temperatures and pressures.
Implementation Method 1
The transformer has a primary winding and multiple secondary windings that are conductively coupled to the sets of switch cells. The transformer is configured to convey an activation control signal from the primary winding to the sets of switch cells via the secondary windings.
Data Source
AI summary
A switching system includes a switching assembly and a transformer. The switching assembly includes multiple sets of switch cells conductively coupled to different power conductors that extend between a power source and a load and conduct different phases of current. Each set of switch cells controls conduction of a different phase of current to the load. The transformer has a primary winding and multiple secondary windings that are conductively coupled to the sets of switch cells. Responsive to receiving an activation control signal from the transformer via the secondary windings, the sets of switch cells are configured to activate to conduct the multiple phases of current from the power source to the load along the power conductors.