Vibration based downhole power generator

• US 6,504,258 B2
• Filed: 06/08/2001
• Issued: 01/07/2003
• Est. Priority Date: 01/28/2000
• Status: Expired due to Fees

• Current Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Original Assignee: Halliburton Energy Services Incorporated (Halliburton Company)
• Inventors: Ringgenberg, Paul David, Bayh, Russell Irving III, Schultz, Roger Lynn, Robison, Clark Edward, Michael, Robert Ken
• Primary Examiner(s): Waks, Joseph
• Application Number:
  US09/876,976
• Publication Number:
  US 20010040379A1
• Time in Patent Office: 578 Days
• Field of Search: 290/1.R, 175/56, 175/104, 310/311, 310/334, 310/339, 310/15, 310/26, 310/30, 310/36
• US Class Current: 290/1.00R
• CPC Class Codes: E21B 28/00 Vibration generating arrangements for boreholes or wells, e.g. for stimulating production for fishing for or freeing objects E21B31/005; for transmitting measuring-signals E21B47/14; for geophysical measurements G01V1/02
• CPC Class Codes: E21B 41/0085 Adaptations of electric power generating means for use in boreholes
• CPC Class Codes: F03G 7/08 recovering energy derived from swinging, rolling, pitching or like movements, e.g. from the vibrations of a machine
• CPC Class Codes: H02N 2/185 using fluid streams

Abstract

A downhole power generator produces electrical power for use by downhole tools. In a described embodiment, a downhole power generator includes a member that is vibrated in response to fluid flow through a housing. Vibration of the member causes a power generating assembly to generate electrical power.

Claims

1. A downhole power generator, comprising:

a housing having a first axial flow passage formed therethrough; and

a power generating structure including a nozzle and a power generating assembly, the nozzle having a second flow passage formed therethrough and in entirely non-valved communication with the first flow passage, the second flow passage having a longitudinal axis, the nozzle vibrating along the longitudinal axis in response to fluid flow through the first and second flow passages, and the power generating assembly producing electrical power in response to the nozzle vibration,

the power generating assembly including a magnet and a coil, one of the magnet and the coil being attached to the nozzle, and the other of the magnet and the coil being attached to the housing so that, as the nozzle vibrates relative to the housing, relative displacement is produced between the coil and the magnet.

2. The downhole power generator according to claim 1, wherein fluid flow through the second flow passage creates a pressure differential across the nozzle, the pressure differential varying and biasing the nozzle in the direction of the fluid flow.

3. The downhole power generator according to claim 2, further comprising a bias member biasing the nozzle in a direction opposite to the direction of the fluid flow.

4. A method of generating power downhole, the method comprising the steps of:

flowing fluid in a first direction through a housing interconnected in a tubular string in a well;

vibrating a structure within the housing in response to the fluid flow through the housing;

generating electrical power in response to the structure vibration;

retrievably securing the structure relative to the housing; and

retrieving the structure from the tubular string separate from the housing while the housing is positioned downhole.

5. A method of generating power downhole, the method comprising the steps of:

flowing fluid in a first direction through a housing interconnected in a tubular string in a well;

vibrating a structure within the housing in response to the fluid flow through the housing; and

generating electrical power in response to the structure vibration,

wherein the structure includes a coil and a magnet,

wherein the vibrating step further comprises displacing the coil relative to the magnet, thereby producing an electric current in the coil in the generating step,

wherein the displacement of the coil relative to the magnet has a natural frequency, and

wherein the vibrating step further comprises displacing the coil relative to the magnet at the natural frequency.

6. The method according to claim 5, wherein the structure further includes an elongated member secured at one end relative to the housing, displacement of the other end of the member relative to the housing having substantially the same natural frequency as displacement of the coil relative to the magnet, and wherein the vibrating step further comprises displacing the other end of the member relative to the housing at the natural frequency.

7. A method of generating power downhole, the method comprising the steps of:

flowing fluid in a first direction through a housing interconnected in a tubular string in a well;

vibrating a structure within the housing in response to the fluid flow through the housing; and

generating electrical power in response to the structure vibration,

wherein the structure includes a magnetostrictive material positioned proximate a coil, and

wherein the vibrating step comprises inducing strain in the magnetostrictive material, thereby producing an electric current in the coil in the generating step.

8. A method of generating power downhole, the method comprising the steps of:

flowing fluid in a first direction through a housing interconnected in a tubular string in a well;

vibrating a structure within the housing in response to the fluid flow through the housing;

generating electrical power in response to the structure vibration; and

electrically interconnecting the structure to a power-consuming downhole tool via an inductive coupling.

9. A method of generating power downhole, the method comprising the steps of:

flowing fluid in a first direction through a housing interconnected in a tubular string in a well;

vibrating a structure within the housing in response to the fluid flow through the housing; and

generating electrical power in response to the structure vibration,

wherein the structure comprises a member,

wherein the vibrating step further comprises displacing the member relative to the housing in response to fluid flow through the member, and

wherein the generating step further comprises inducing a strain in a magnetostrictive material proximate a coil, thereby creating an electric current in the coil, in response to displacement of the member relative to the housing.

10. A method of generating power downhole, the method comprising the steps of:

flowing fluid in a first direction through a housing interconnected in a tubular string in a well;

vibrating a structure within the housing in response to the fluid flow through the housing, the structure having an interior;

generating electrical power in response to the structure vibration; and

regulating the vibration of the structure in response to the fluid flow through the housing, the regulating step being performed in response to a change in the fluid flow through the housing effected by creating relative movement between the structure and a member projecting into the interior of the structure.

11. A downhole power generator, comprising:

a housing having a first flow passage formed therethrough; and

a power generating structure including a power generating assembly and a vibrating member, the member vibrating in response to fluid flow through the first flow passage, and the power generating assembly generating electrical power in response to vibration of the member,

wherein the power generating assembly includes a coil positioned proximate a magnetostrictive material, vibration of the member causing strain in the magnetostrictive material.

12. A downhole power generator, comprising:

a housing having a first flow passage formed therethrough; and

a power generating structure including a power generating assembly and a vibrating member, the member vibrating in response to fluid flow through the first flow passage, and the power generating assembly generating electrical power in response to vibration of the member,

wherein the member has a second flow passage formed therethrough in communication with the first flow passage, the member vibrating in response to fluid flow through the second flow passage, and

wherein the power generating assembly includes a magnetostrictive material disposed between the member and the housing so that, as the member is vibrated, strain is induced in the magnetostrictive material.

13. A downhole power generator, comprising:

a housing having a first flow passage formed therethrough; and

a power generating structure including a power generating assembly and a vibrating member, the member vibrating in response to fluid flow through the first flow passage, and the power generating assembly generating electrical power in response to vibration of the member,

wherein the power generating structure is retrievably secured relative to the housing while the housing is positioned downhole.

14. A downhole power generator, comprising:

a housing having a first flow passage formed therethrough; and

a power generating structure including a power generating assembly and a vibrating member, the member vibrating in response to fluid flow through the first flow passage, and the power generating assembly generating electrical power in response to vibration of the member,

wherein the power generating structure is electrically interconnected to the housing via an inductive coupling.

15. A downhole power generator comprising:

a housing having a first flow passage formed therethrough;

a power -generating structure including a power generating assembly and a vibrating member, the member vibrating in response to fluid flow through the first flow passage, and the power generating assembly generating electrical power in response to vibration of the member; and

a regulating member extending into the vibrating member, the regulating member regulating the flow responsive vibration of the vibrating member, and the regulating member being responsive to a change in the fluid flow through the housing.

16. The downhole power generator according to claim 15, wherein the regulating member regulates a velocity of the fluid flow in the housing.

17. The downhole power generator according to claim 15, wherein the regulating member varies a flow area in the housing.

18. The downhole power generator according to claim 15, wherein there is a relative displacement between the regulating member and the vibrating member in response to the change in the fluid flow through the housing.

19. A downhole power generator, comprising:

a generally tubular housing having an axial flow passage formed therethrough; and

a power generating structure including a power generating assembly and an elongated member extending into the flow passage, at least one end of the member vibrating laterally relative to the housing in response to fluid flow through the flow passage, and the power generating assembly being attached to the member so that as the member vibrates, the power generating assembly generates electrical power,

wherein the power generating assembly includes a coil and a magnetostrictive material, vibration of the member inducing strain in the magnetostrictive material and generating an electric current in the coil.

20. A downhole power generator, comprising:

a generally tubular housing having an axial flow passage formed therethrough; and

a power generating structure including a power generating assembly and an elongated member extending into the flow passage, at least one end of the member vibrating laterally relative to the housing in response to fluid flow through the flow passage, and the power generating assembly being attached to the member so that as the member vibrates, the power generating assembly generates electrical power,

wherein the power generating assembly includes a mass and a piezoelectric material, vibration of the member causing the mass to induce strain in the piezoelectric material.

21. A downhole power generator, comprising:

a housing having a first axial flow passage formed therethrough; and

a power generating structure including a nozzle and a power generating assembly, the nozzle having a second flow passage formed therethrough in communication with the first flow passage, the nozzle vibrating axially relative to the housing in response to fluid flow through the first and second flow passages, the power generating assembly producing electrical power in response to the nozzle vibration, and wherein the power generating assembly includes a magnetostrictive material disposed proximate a coil and axially between at least a portion of the nozzle and at least a portion of the housing so that, as the nozzle axially vibrates relative to the housing, strain is repetitively induced in the magnetostrictive material, thereby producing a magnetic field about the coil.