Acoustic transmitter for transmitting a signal through a downhole medium
09797241 · 2017-10-24
Assignee
Inventors
Cpc classification
E21B47/16
FIXED CONSTRUCTIONS
B06B1/0215
PERFORMING OPERATIONS; TRANSPORTING
International classification
E21B47/16
FIXED CONSTRUCTIONS
B06B1/02
PERFORMING OPERATIONS; TRANSPORTING
Abstract
An acoustic transmitter for transmitting an acoustic signal through a downhole medium includes a voltage source; a composite load; and switching circuitry that applies voltage from the voltage source across the composite load in response to a drive signal. The composite load includes charge control circuitry, in the form of at least one inductor, connected electrically in series with a piezoelectric transducer that may be electrically modeled as a capacitor.
Claims
1. A drilling tool comprising an acoustic transmitter for transmitting an acoustic signal through a drillstring, the transmitter comprising: (a) a voltage source; (b) a piezoelectric transducer and two metal shoulders constraining the piezoelectric transducer, the metal shoulders launching the acoustic signal into the drillstring when the piezoelectric transducer expands and contracts; (c) charge control circuitry comprising a pair of inductors, wherein the piezoelectric transducer is connected in series between the pair of inductors, the piezoelectric transducer and the charge control circuitry collectively comprising a composite load; and (d) switching circuitry comprising: (i) a control terminal for receiving a drive signal; (ii) a supply terminal connected to the voltage source; and (iii) a pair of output terminals across which the composite load is connected, wherein voltage from the voltage source is applied across the output terminals in response to the drive signal, wherein the composite load has a series resonant frequency that is at least four times the frequency of the acoustic signal.
2. The drilling tool of claim 1, wherein the pair of inductors have equal inductances.
3. The drilling tool of claim 1, wherein the charge control circuitry comprises two groups of inductors having equal inductances, and wherein one of the two groups of inductors comprises one of the pair of inductors and the other of the two groups of inductors comprises the other of the pair of inductors.
4. The drilling tool of claim 2, wherein the inductances of the inductors are selected such that total inductance of the composite load permits the transmitter to have a slew rate sufficient for the frequency of the acoustic signal.
5. The drilling tool of claim 1, wherein the voltage is applied across the output terminals in a forward polarity when the drive signal is in a first state, and the voltage is applied across the output terminals in a reverse polarity when the drive signal is in a second state.
6. The drilling tool of claim 1, wherein the switching circuitry comprises an H-bridge comprising power transistors as switches and a freewheeling diode placed across the output terminals of each of the power transistors.
7. The drilling tool of claim 1, further comprising a controller connected to the control terminal that outputs a pulse width modulation signal as the drive signal.
8. The drilling tool of claim 1, further comprising a battery electrically coupled to a DC to DC voltage converter whose output is connected to the supply terminal.
9. An acoustic transmission system for transmitting an acoustic signal through a drillstring, the system comprising: (a) a transmitter located either within a downhole tool or on surface, the transmitter comprising: (i) a voltage source; (ii) a piezoelectric transducer and two metal shoulders constraining the piezoelectric transducer, the metal shoulders launching the acoustic signal into the drillstring when the piezoelectric transducer expands and contracts; (iii) charge control circuitry comprising a pair of inductors, wherein the piezoelectric transducer is connected in series between the pair of inductors, the piezoelectric transducer and the charge control circuitry collectively comprising a composite load; and (iv) switching circuitry comprising: (1) a control terminal for receiving a drive signal; (2) a supply terminal connected to the voltage source; and (3) a pair of output terminals across which the composite load is connected, wherein voltage from the voltage source is applied across the output terminals in response to the drive signal; (b) a receiver located within the downhole tool when the transmitter is on surface and located on surface when the transmitter is within the downhole tool, the receiver configured to receive the acoustic signal after propagating through the drillstring; and (c) a demodulator communicatively coupled to the receiver and configured to recover transmitted data from the received acoustic signal, wherein the composite load has a series resonant frequency that is at least four times the frequency of the acoustic signal.
10. A method for transmitting an acoustic signal through a drillstring, the method comprising applying a voltage across a composite load comprising a pair of inductors and a piezoelectric transducer connected in series between the pair of inductors in order to generate the acoustic signal, the piezoelectric transducer constrained by metal shoulders that launch the acoustic signal into the drillstring when the piezoelectric transducer expands and contracts in response to the voltage, wherein the composite load has a series resonant frequency that is at least four times the frequency of the acoustic signal.
11. The method of claim 10, wherein the pair of inductors have equal inductances.
12. The method of claim 10, wherein the composite load comprises two groups of inductors having equal inductances, and wherein one of the two groups of inductors comprises one of the pair of inductors and the other of the two groups of inductors comprises the other of the pair of inductors.
13. The method of claim 10, wherein the inductance of the at least one inductor is selected such that total inductance of the composite load permits the transmitter to have a slew rate sufficient for the frequency of the acoustic signal.
14. The method of claim 10, wherein the voltage is applied to the composite load via switching circuitry controlled by the drive signal, the voltage being applied across the composite load in a forward polarity when the drive signal is in a first state and in a reverse polarity when the drive signal is in a second state.
15. The method of claim 14, wherein the switching circuitry comprises an H-bridge comprising power transistors as switches and a freewheeling diode placed across the output terminals of each of the power transistors.
16. The method of claim 14, wherein the drive signal is modulated using pulse width modulation.
17. A drilling tool comprising an acoustic transmitter for transmitting an acoustic signal through a drillstring, the transmitter comprising: (a) a voltage source; (b) a piezoelectric transducer and two metal shoulders constraining the piezoelectric transducer, the metal shoulders launching the acoustic signal into the drillstring when the piezoelectric transducer expands and contracts; (c) charge control circuitry comprising a pair of inductors, wherein the piezoelectric transducer is connected in series between the pair of inductors, the piezoelectric transducer and the charge control circuitry collectively comprising a composite load; and (d) switching circuitry comprising: (i) a control terminal for receiving a drive signal; (ii) a supply terminal connected to the voltage source; and (iii) a pair of output terminals across which the composite load is connected, wherein voltage from the voltage source is applied across the output terminals in response to the drive signal, wherein total inductance of the charge control circuitry connected in series with the piezoelectric transducer is
18. The drilling tool of claim 17, wherein the pair of inductors have equal inductances.
19. The drilling tool of claim 17, wherein the charge control circuitry comprises two groups of inductors having equal inductances, and wherein one of the two groups of inductors comprises one of the pair of inductors and the other of the two groups of inductors comprises the other of the pair of inductors.
20. The drilling tool of claim 17, wherein the voltage is applied across the output terminals in a forward polarity when the drive signal is in a first state, and the voltage is applied across the output terminals in a reverse polarity when the drive signal is in a second state.
21. The drilling tool of claim 17, wherein the switching circuitry comprises an H-bridge comprising power transistors as switches and a freewheeling diode placed across the output terminals of each of the power transistors.
22. The drilling tool of claim 17, further comprising a controller connected to the control terminal that outputs a pulse width modulation signal as the drive signal.
23. The drilling tool of claim 17, further comprising a battery electrically coupled to a DC to DC voltage converter whose output is connected to the supply terminal.
24. An acoustic transmission system for transmitting an acoustic signal through a drillstring, the system comprising: (a) a transmitter located either within a downhole tool or on surface, the transmitter comprising: (i) a voltage source; (ii) a piezoelectric transducer and two metal shoulders constraining the piezoelectric transducer, the metal shoulders launching the acoustic signal into the drillstring when the piezoelectric transducer expands and contracts; (iii) charge control circuitry comprising a pair of inductors, wherein the piezoelectric transducer is connected in series between the pair of inductors, the piezoelectric transducer and the charge control circuitry collectively comprising a composite load; and (iv) switching circuitry comprising: (1) a control terminal for receiving a drive signal; (2) a supply terminal connected to the voltage source; and (3) a pair of output terminals across which the composite load is connected, wherein voltage from the voltage source is applied across the output terminals in response to the drive signal; (b) a receiver located within the downhole tool when the transmitter is on surface and located on surface when the transmitter is within the downhole tool, the receiver configured to receive the acoustic signal after propagating through the drillstring; and (c) a demodulator communicatively coupled to the receiver and configured to recover transmitted data from the received acoustic signal, wherein total inductance of the charge control circuitry connected in series with the piezoelectric transducer is
25. A method for transmitting an acoustic signal through a drillstring, the method comprising applying a voltage across a composite load comprising a pair of inductors and a piezoelectric transducer connected in series between the pair of inductors in order to generate the acoustic signal, the piezoelectric transducer constrained by metal shoulders that launch the acoustic signal into the drillstring when the piezoelectric transducer expands and contracts in response to the voltage, wherein total inductance connected in series with the piezoelectric transducer is
26. The method of claim 25, wherein the pair of inductors have equal inductances.
27. The method of claim 25, wherein the composite load comprises two groups of inductors having equal inductances, and wherein one of the two groups of inductors comprises one of the pair of inductors and the other of the two groups of inductors comprises the other of the pair of inductors.
28. The method of claim 25, wherein the voltage is applied to the composite load via switching circuitry controlled by the drive signal, the voltage being applied across the composite load in a forward polarity when the drive signal is in a first state and in a reverse polarity when the drive signal is in a second state.
29. The method of claim 28, wherein the switching circuitry comprises an H-bridge comprising power transistors as switches and a freewheeling diode placed across the output terminals of each of the power transistors.
30. The method of claim 28, wherein the drive signal is modulated using pulse width modulation.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) In the accompanying drawings, which illustrate one or more example embodiments:
(2)
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DETAILED DESCRIPTION
(10) Directional terms such as “top”, “bottom”, “upwards”, “downwards”, “vertically”, and “laterally” are used in the following description for the purpose of providing relative reference only, and are not intended to suggest any limitations on how any article is to be positioned during use, or to be mounted in an assembly or relative to an environment. Additionally, the term “couple” and variants of it such as “coupled”, “couples”, and “coupling” as used in this description is intended to include indirect and direct connections unless otherwise indicated. For example, if a first device is coupled to a second device, that coupling may be through a direct connection or through an indirect connection via other devices and connections. Similarly, if the first device is communicatively coupled to the second device, communication may be through a direct connection or through an indirect connection via other devices and connections.
(11) Data may be transmitted during oil and gas drilling operations using any one of several techniques. For example, data may be transmitted using acoustic telemetry, in which an acoustic signal propagates as a wave along a transmission medium such as a drill string. Alternatively, data may be transmitted using mud-pulse telemetry, in which the data is encoded as pressure pulses that are transmitted via the drilling fluid or mud. Also alternatively, wireline telemetry may be used, in which data is transmitted in the form of electrical signals along cables. The embodiments described herein are directed at acoustic telemetry.
(12) Acoustic telemetry typically permits communication at a higher data rate than competing technologies such as mud pulse and electromagnetic telemetry, is unaffected by the characteristics of the formations surrounding the drillstring, and also offers an unobstructed tool bore that facilitates ease of operation. Data transmitted using acoustic telemetry is carried by an acoustic signal comprising mechanical, extensional waves that are launched into the drill pipe by an electromechanical transducer located either within a downhole tool or from the surface.
(13) A piezoelectric stack is commonly used as the electromechanical transducer that launches the extensional waves into the drill pipe. The stack comprises a series of thin piezoelectric discs that are mounted on a mandrel and constrained between two metal shoulders. Electrically the discs are connected in parallel with thin metal electrodes interleaved between the discs. As a result the stack's electrical behavior is primarily capacitive. Applying a high voltage charges the stack and causes it to increase or decrease in length. It is this deflection that launches the extensional waves into the drill pipe.
(14) It is generally recognized that the periodic structure of drillstring creates a structure whose frequency response may be characterized as a comb filter comprising a series of passbands alternating with stopbands (D.S. Drumheller, Acoustic Properties of Drill Strings, J. Acoustical Society of America, 85: 1048-1064, 1989), and that acoustic signals will propagate within one or more of the passbands. Accordingly, the acoustic signal comprises one or more carrier waves at frequencies within one or more passbands of the drillstring that may be modulated so as to transmit data (for example, downhole sensor data or uphole/downhole control data) along the drillstring. However, due to the need for increasing data rates and the bandwidth limitations of the drillstring it is often desirable to transmit digitally encoded signals with an increased number of bits per symbol. The desired acoustic signal may therefore comprise a complex waveform requiring considerable power to generate. Existing downhole acoustic transmitters, however, are limited in their ability to produce acoustic signals with complex waveforms, and fail to efficiently utilize the limited power resources available downhole.
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(16) The transformer's 18 secondary winding is connected in parallel to another capacitor 20, which models the piezoelectric stack used to generate the acoustic signal (the capacitor 20 is hereinafter the “stack capacitor 20”). The transformer's 18 secondary winding and the stack capacitor 20 collectively comprise a parallel LC circuit. The transformer's 18 secondary winding is tapped at a location so that the parallel LC circuit is in resonance when operated at a frequency that falls within one of the acoustic passbands of the drillstring.
(17) In order to operate the transmitter 10 to transmit a sinusoidal waveform the parallel LC circuit is subjected to a series of current impulses. Each impulse is created by momentarily connecting the battery 12 to ground through the primary winding of the transformer 18 by applying a voltage to the transistor's 22 gate 24 sufficient to switch the transistor 22 on. This in turn excites the parallel LC circuit to oscillate at its natural frequency. The impulses are separated by the duration of one full cycle of the desired output frequency of the acoustic signal and the timing of the impulses can force the acoustic signal to be either higher or lower in frequency than the natural frequency of the parallel LC circuit. Decreasing the time between impulses increases the output frequency while increasing the time between impulses reduces the output frequency.
(18) The transmitter 10 of
(19) Accordingly, the following embodiments are directed at an acoustic transmitter that overcomes at least one of the above limitations. For example, the following embodiments include one or more of the following features: (a) the use of digital and solid-state components, which preclude the requirement for a transformer and consequently increase power efficiency and reduce the size of the transmitter; (b) the ability to generate acoustic signals that have been modulated using techniques other than constant envelope frequency or phase modulation; and (c) the ability to generate acoustic signals for transmission over any one or more of the drillstring's frequency passbands, thereby permitting use of a greater proportion of the drillstring's bandwidth for data transmission.
Acoustic Transmitter Block Diagram
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(21) In the depicted example embodiment the controller 160 comprises a digital signal processor that outputs the PWM drive signal, but in alternative embodiments may comprise a processor, microcontroller, or other suitable analog, digital, or mixed signal circuit, such as a pulse-width modulator capable of providing the drive signal. The use of controlled packets of charge, regulated by the charge control circuitry 132 as discussed in relation to Equations 1 through 5 below, to drive the piezoelectric transducer 140 allows for the generation of varied and complex acoustic signals, including those with non-constant envelopes and those that transmit data using the drillstring's different passbands.
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(23) Switching Circuitry
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(25) While the switching circuitry 120 shown in
(26) Charge Control Circuitry
(27) The composite load comprising the charge control circuitry 132 and the piezoelectric stack 140 are connected across the H-bridge's output terminals 128. This embodiment of the charge control circuitry 132 comprises the symmetric pair of inductors, with one inductor connected to one terminal of the piezoelectric stack 140 and the other inductor connected to the other terminal of the piezoelectric stack 140. While the depicted embodiment shows the charge control circuitry 132 comprising only two inductors, in alternative embodiments (not depicted) one or both of these inductors comprising the symmetric pair may be replaced with a group of inductors electrically connected together in series. In the depicted example embodiment, the series LC resonance created by the inductors and the piezoelectric stack 140 is well above the frequency of the acoustic signal; in
(28) Pulse Width Modulation (PWM) is a common modulation method used to drive an H-bridge in applications such as motor control or electronic voltage converters. The generation of a PWM control signal and the operation of an H-bridge are well understood by those versed in the art and are documented in detail in several references including Power Electronics: Converters, Applications and Design; Mohan, Underland and Robbins; pp. 188-194.
(29) In this embodiment a PWM representation of the desired acoustic waveform is used to drive the H-bridge. The composite load, which is a series LC circuit comprising the piezoelectric stack 140 electrically connected between the two inductors that comprise the charge control circuitry 132, is connected across the output terminals 128 and is subject to a series of alternating rectangular voltage steps at the level of ±V.sub.sapplied to the supply terminal 122 with a duty cycle determined by the PWM signal. The resulting current waveform through the composite load is a function of the step response of the composite load, which in turn is determined by the value of the series inductors given a fixed capacitive value for the piezoelectric stack 140. The amount of charge transferred to the piezoelectric stack 140 during a cycle of the PWM waveform can be controlled by the correct sizing of the series inductors, as discussed below in respect of Equations 1 through 5, which in turn indirectly controls the stack's 140 voltage and deflection.
(30) The step function of the series LC circuit can be simplified if the clock period T for the PWM signal is short enough that a simple linear approximation for the inductor current can be used. Referring to
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(32) Again referring to
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(34) Assuming a sinusoidal voltage across the piezoelectric stack 140 of V.sub.stack=V.sub.psin(ωt) in which ω is the desired radial frequency of the acoustic signal and V.sub.p is the maximum signal voltage across the piezoelectric stack 140, the maximum voltage slew rate and greatest current draw occurs at the zero crossing point of V.sub.stack. Assuming a sufficiently small value of ωT, the incremental stack voltage required during the clock cycle T starting at t=0 can be approximated as:
V.sub.T=V.sub.psin(ωT)≅V.sub.pωT (4)
(35) Then given the capacitance C of the stack 140 and the supply voltage V.sub.s, the total series inductance L of the charge control circuitry 132 and consequently the composite load can be shown to be:
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(37) If the total series inductance L were zero, the voltage across the piezoelectric transducer 140 would follow that of the drive signal. Conversely, if the total series inductance L were too high, the voltage across the piezoelectric transducer 140 would be unable to transition quickly enough to accommodate the slew rate required by the acoustic signal. Selecting the total series inductance L in accordance with Equation 5 allows the voltage across the piezoelectric stack 140 to deviate from the drive signal, yet still be sufficiently responsive to the drive signal to accommodate the acoustic signal slew rate.
(38) Referring now to
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(41) For the sake of convenience, the example embodiments above are described as various interconnected functional blocks or distinct software modules. This is not necessary, however, and there may be cases where these functional blocks or modules are equivalently aggregated into a single logic device, program or operation with unclear boundaries. In any event, the functional blocks and software modules or features of the flexible interface can be implemented by themselves, or in combination with other operations in either hardware or software.
(42) It is contemplated that any part of any aspect or embodiment discussed in this specification can be implemented or combined with any part of any other aspect or embodiment discussed in this specification.
(43) While particular embodiments have been described in the foregoing, it is to be understood that other embodiments are possible and are intended to be included herein. It will be clear to any person skilled in the art that modifications of and adjustments to the foregoing embodiments, not shown, are possible.