Current-shaping circuit for use with magnetic couplers downhole

Patent metadata

Field	Value
Publication number	US-11081989-B2
Application number	US-201515754926-A
Country	US
Kind code	B2
Filing date	Nov 6, 2015
Priority date	Nov 6, 2015
Publication date	Aug 3, 2021
Grant date	Aug 3, 2021

Abstract

A power generation device is provided. The power generation device can include a magnetic coupler. The magnetic coupler can be associated with a maximum torque output. The maximum torque output of the magnetic coupler can be based on a size of the magnetic coupler. The power generation device can also include an alternator coupled to the magnetic coupling device. The alternator can convert kinetic energy received from the magnetic coupling device into a current. The kinetic energy can be generated by the magnetic coupler using a rotational force transferred across the magnetic coupling device. The power generation device can also include a power converter device coupled to the alternator to shape the current from the alternator such that the maximum torque output is sufficient to cause the power converter to output a threshold current sufficient for operating a well tool powered using the power generation device.

First claim

What is claimed is:

1. A power generation device, the power generation device comprising:
a magnetic coupling device associated with a maximum torque output based on a size of the magnetic coupling device;
an alternator coupled to the magnetic coupling device to convert kinetic energy received from the magnetic coupling device into a current, the kinetic energy being generated by the magnetic coupling device using a rotational force transferred across the magnetic coupling device; and
a power converter device coupled to the alternator to shape the current from the alternator such that the maximum torque output of the magnetic coupling device is sufficient to cause the power converter device to output a threshold current sufficient for operating a well tool powered using the power generation device.

2. The power generation device of claim 1 , wherein the magnetic coupling device is a radial magnetic coupler or an axial magnetic coupler.

3. The power generation device of claim 1 , wherein the power converter device includes at least one of an active rectifier, a Vienna converter, a single-phase converter based three-phase circuit, or a multi-switch topology with a diode bridge rectifier to shape the current from the alternator.

4. The power generation device of claim 1 , wherein the power converter device is coupled to the alternator to shape the current into a sinusoidal current waveform.

5. The power generation device of claim 1 , wherein the power converter device is coupled to the alternator to convert the current from the alternator into a direct current and eliminating a high frequency component of the rotational force.

6. The power generation device of claim 4 , wherein the power converter device further comprises a pair of switches to control a flow of the current to shape the current into the sinusoidal current waveform.

7. The power generation device of claim 6 , wherein each switch in the pair of switches is a rectifier switch or a transistor.

8. The power generation device of claim 6 , wherein each switch in the pair of switches is configured to receive a signal for configuring each switch in the pair of switches to be in an ON or OFF state for controlling the flow of the current for shaping the current into the sinusoidal current waveform.

9. A system comprising:
an electronic tool; and
a power delivery device configured to provide power to the electronic tool, the power delivery device comprising:
a magnetic coupling device associated with a maximum torque output based on a size of the magnetic coupling device,
an alternator coupled to the magnetic coupling device to convert kinetic energy received from the magnetic coupling device into a current, the kinetic energy being generated by the magnetic coupling device using a rotational force transferred across the magnetic coupling device, and
a power converter device coupled to the alternator to shape the current from the alternator such that the maximum torque output of the magnetic coupling device is sufficient to cause the power delivery device to output a threshold current sufficient for operating the electronic tool.

10. The system of claim 9 , wherein the magnetic coupling device is a radial magnetic coupler or an axial magnetic coupler.

11. The system of claim 9 , wherein the power converter device is coupled to the alternator to shape the current from the alternator into a sinusoidal current waveform.

12. The system of claim 11 , wherein the power converter device further comprises a pair of switches to control a flow of the current for shaping the current into the sinusoidal current waveform.

13. The system of claim 9 , wherein the power converter device is coupled to the alternator to eliminate a high frequency component of the rotational force.

14. A method comprising:
determining a maximum size of a magnetic coupling device based on a size of a wellbore;
determining a maximum amount of torque that can be transferred across the magnetic coupling device for powering a well tool, based on the maximum size of the magnetic coupling device;
determining an amount of torque needed for providing power to the well tool; and
configuring a system for using the magnetic coupling device to transfer the amount of torque needed for providing the power to the well tool, wherein the system includes a power converter device configured to shape a current such that the maximum amount of torque associated with the magnetic coupling component is sufficient to cause the power converter device to output an amount of current that is sufficient for operating the well tool.

15. The method of claim 14 , wherein the current is received by the power converter device from an alternator, and wherein configuring the system for using the magnetic coupling device to transfer the amount of torque needed for providing the power to the well tool includes configuring the power converter device for shaping the current from the alternator into a sinusoidal current waveform.

16. The method of claim 14 , wherein determining the maximum size of the magnetic coupling device includes determining dimensions of the magnetic coupling device based on a value of a constant component of the amount of torque needed for providing the power to the well tool.

17. The method of claim 14 , wherein the current is received by the power converter device from an alternator, and wherein configuring the system for using the magnetic coupling device to transfer the amount of torque needed for providing the power to the well tool further includes:
configuring the power converter device to convert the current from the alternator into a direct current and eliminate a high frequency component of the amount of torque needed for providing the power to the well tool.

18. The method of claim 17 , wherein configuring the power converter device to convert the current from the alternator into the direct current includes converting, by a rectifier or transistor, an alternating current from the alternator into the direct current.

19. The method of claim 15 , wherein shaping the current from the alternator into the sinusoidal current waveform includes using at least a pair of switches to control a flow of the current.

20. The method of claim 19 , wherein using at least the pair of switches includes configuring each switch in the pair of switches to be in an ON or OFF state based on a measured current value and a specified current value.

21. A method comprising:
determining an amount of torque needed for providing power to a well tool;
determining a maximum size of a magnetic coupling device based on a size of a wellbore, wherein determining the maximum size of the magnetic coupling device involves determining dimensions of the magnetic coupling device based on a value of a constant component of the amount of torque needed for providing power to the well tool; and
configuring a system for using the magnetic coupling device to transfer the amount of torque needed for providing the power to the well tool.

Assignees

• Halliburton Energy Services Inc

Inventors

• Douglas Hugh

Classifications

• H02K49/108

  with an axial air gap · CPC title

• H02P9/48

  Arrangements for obtaining a constant output value at varying speed of the generator, e.g. on vehicle (H02P9/04 - H02P9/46 take precedence) · CPC title

• H02P9/02 Primary

  Details {of the control} · CPC title

• E21B41/0085 Primary

  Adaptations of electric power generating means for use in boreholes · CPC title

• H02K49/104

  Magnetic couplings consisting of only two coaxial rotary elements, i.e. the driving element and the driven element · CPC title