Unified Electronic Interface Module for Downhole Tool Bus
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Solution Overview
Problem
The development of downhole tools with complex electronic assemblies is hindered by the need for customized and costly wire harnesses, which are bulky, fragile, and inefficient, leading to lengthy and expensive development processes that struggle to meet the harsh conditions and rapid changes in the oil/gas industry.
Innovation Solution
A unified electronic interface module that allows direct connection of electronic assemblies to a layered tool bus, reducing the number of connections needed and enabling streamlined testing and simulation, thereby simplifying the development process and improving tool reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If customized wire harnesses are used to interconnect electronic assemblies, then reliable electrical connections are achieved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent merges the functions of multiple separate wire harnesses and connectors into a single integrated circuit board that provides all necessary electrical interconnections between electronic assemblies. This consolidation eliminates the need for complex customized wire harnesses while maintaining reliable electrical connections through standardized PCB trace routing and solder joints.
Solution Approach 2:
The patent replaces the mechanical wire harness system with an electronic circuit board system. Instead of using physical wires and mechanical connectors, the electrical interconnections are achieved through conductive traces on the PCB, eliminating the mechanical complexity of wire routing, connector assembly, and harness management while improving connection reliability.
2Device complexity
If standardized connectors are used instead of customized wire harnesses, then manufacturing cost and complexity are reduced, but adaptability to different tool configurations is limited
Solution Approach 1:
The patent designs the circuit board with universal mounting interfaces and standardized connection points that can accommodate different electronic assemblies in various configurations. The PCB includes multiple connection zones and flexible routing that allow the same board design to serve different tool configurations, eliminating the need for customized wire harnesses for each configuration while maintaining adaptability.
3Ease of operation
If traditional wire harness interconnection methods are used, then electronic assemblies can be interconnected, but development time and testing duration increase
Solution Approach 1:
The patent incorporates all necessary electrical interconnections into the circuit board design during the manufacturing process, rather than assembling wire harnesses during tool assembly. The PCB is pre-configured with all required connection paths, eliminating time-consuming wire routing, connector attachment, and harness assembly steps during tool development and testing phases.
Data Source
AI summary
An interface module has an outward interface with at least two ports for directly connecting to separate sections of a tool bus. The outward interface may have two uplink ports and one downlink port for layered tool bus applications. Each port has two electrical contacts for creating an electrical path between electronic assemblies with combined power & data transmission (CPDT) using a transmission line. A power port is connectable to an external power source via a common electrical path. A standardized inward interface of the interface module provides data and communication contact groups for data and power communication with assembly electronics. The interface module is implemented using advanced electronics packaging technology for easy installation on a printed circuit board. The interface module facilitates a streamlined downhole electronic testing configuration for testing electronics as they are developed prior to completion of development of dependent components.