Well Tool Position Sensing Without Magnetic Hysteresis
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Solution Overview
Problem
Conventional position measuring devices for well site tools, such as position sensor assemblies (PSAs), suffer from precision loss due to magnetic hysteresis and friction, requiring frequent recalibration, which increases operational time and costs.
Innovation Solution
The use of optical-based position sensors, vibration sensors, and radiation-based systems to measure and verify the position of moving mechanisms in well site tools, reducing reliance on magnetic coupling and minimizing friction, thereby enhancing accuracy and reducing recalibration frequency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional position sensor assemblies (PSA) utilize magnets to couple the PSA to the valve magnetic assembly (VMA), then the positioning information can be obtained, but precision is lost and calibration is interfered with due to friction and magnetic hysteresis
Solution Approach 1:
The patent replaces the magnetic coupling system with an optical system. An optical sensor assembly uses a light source and photodetector to detect the position of a reflective element attached to the moving mechanism, eliminating magnetic fields and their associated hysteresis effects. This substitution of mechanical/magnetic system with optical system resolves the contradiction by maintaining measurement capability while eliminating the sources of precision loss and calibration instability.
Solution Approach 2:
The patent introduces an optical intermediary (light) as the mediator between the sensor and the moving mechanism. Instead of direct magnetic coupling, the optical system uses reflected light to transmit position information, creating an indirect measurement path that avoids the harmful interactions of magnetic hysteresis and friction, thereby improving both measurement precision and calibration stability.
2Measurement precision
If the moving mechanism is fully moved to one position for periodic calibration, then the moving mechanism can be calibrated with the PSA, but time is lost and positioning imprecision occurs prior to re-calibration
Solution Approach 1:
The optical measurement system provides continuous, non-contact position measurement that does not require periodic mechanical calibration. The optical sensor continuously tracks the position of the reflective element, maintaining accuracy throughout operation without needing to return to reference positions for recalibration, thus eliminating the time loss and positioning imprecision associated with periodic calibration cycles.
Solution Approach 2:
The optical sensing system enables continuous position measurement throughout the operating range of the moving mechanism. Unlike magnetic systems that require periodic re-calibration, the optical system maintains measurement continuity and accuracy without interruption, allowing the useful action of position measurement to continue uninterrupted throughout the entire operational cycle.
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
These systems enable precise and efficient positioning of well site tools by minimizing magnetic hysteresis and friction, allowing for faster movement to specified positions with reduced operational time and cost.
Implementation Method 1
measuring a data parameter using the sensor, wherein the sensor is one or more of a vibration sensor and an accelerometer, and the data parameter is one or more of a frequency of vibration
Implementation Method 2
measuring a data parameter using the sensor, wherein the sensor is one or more of a vibration sensor and an accelerometer, and the data parameter is one or more of a frequency of vibration, a time interval, and an acceleration
Implementation Method 3
The use of optical-based position sensors, vibration sensors, and radiation-based systems to measure and verify the position of moving mechanisms in well site tools
Data Source
AI summary
This disclosure presents an apparatus to improve the position sensing of a moving mechanism, such as a fluid valve located within a borehole. The apparatus can utilize a light beam or an optical fiber to measure changes in the position sensor. The smaller and lighter apparatus can improve the accuracy of the sensing mechanism. In addition, three systems are presented. The first system utilizes a vibration sensor, such as a MEMS, and an accelerometer to calculate changes in the mechanism position of the moving mechanism. The second system utilizes a radiation source and detector combination, along with a moving radiation shield to provide more accurate position sensing than conventional techniques. In addition, a lens-based system is presented, that when combined with a radiation source, can calculate position information by detecting the diffusion or dispersal of the radiation against a radiation detector.