Downhole torodial generator with central passage

• US 8,421,287 B2
• Filed: 04/26/2010
• Issued: 04/16/2013
• Est. Priority Date: 04/26/2010
• Status: Expired due to Fees

• Current Assignee: Novatek IP, LLC
• Original Assignee: David R. Hall
• Inventors: Hall, David R., Dahlgren, Scott S.
• Primary Examiner(s): Nguyen, Tran
• Assistant Examiner(s): Andrews, Michael
• Application Number:
  US12/767,332
• Publication Number:
  US 20110260457A1
• Time in Patent Office: 1,086 Days
• Field of Search: 310/87, 310/85, 310/216.023, 310/216.033, 310/216.039, 310/216.074, 310/216.077, 310/216.091, 310/216.094
• US Class Current: 310/87
• CPC Class Codes: E21B 21/103 Down-hole by-pass valve arrangements, i.e. between the inside of the drill string and the annulus valves specifically for maintaining circulation of drilling fluid while connecting or disconnecting tubular joints E21B21/019
• CPC Class Codes: E21B 41/0085 Adaptations of electric power generating means for use in boreholes
• CPC Class Codes: H02K 1/145 having an annular coil, e.g. of the claw-pole type
• CPC Class Codes: H02K 21/145 having an annular armature coil with homopolar co-operation H02K21/20
• CPC Class Codes: H02K 7/1823 structurally associated with turbines or similar engines

Abstract

What is claimed is a downhole tool string component comprising a generator. The generator may comprise a toroidal stator comprising an interior channel formed between inward extending stator poles. A coil of wire is disposed within the interior channel, and a plurality of magnets are rotatably disposed proximate each pole.

A downhole tool string component comprises a bore to receive a flow of drilling fluid comprising a central passage and at least one peripheral passage. A compliant member is disposed within the bore and forms an internal diameter of the central passage, and at least one opening. The at least one opening comprises an internal area within the compliant member to divert the flow of drilling fluid into the at least one peripheral passage. The compliant member comprises a compliant property allowing the internal area of the at least one opening to change thus changing the amount of diverted drilling fluid.

Claims

1. A generator, comprising:

a toroidal stator comprising an interior channel formed between inward extending stator poles;

a coil of wire disposed within the interior channel;

a rotatable conduit extending through the toroidal stator; and

a plurality of magnets secured around a perimeter of the rotatable conduit and rotatably disposed proximate each stator pole;

wherein the rotatable conduit shields the toroidal stator, coil of wire, and plurality of magnets from a fluid flow passing through the rotatable conduit; and

wherein the rotatable conduit comprises openings disposed around the perimeter of the rotatable conduit and the openings channel the fluid flow into the rotatable conduit.

2. The generator of claim 1, wherein the inward extending stator poles are paired with mating stator poles on opposing sides of the interior channel.

3. The generator of claim 1, wherein the inward extending stator poles are circumferentially separated by a plurality of slots.

4. The generator of claim 3, wherein the inward extending stator poles are evenly spaced by a plurality of matching slots.

5. The generator of claim 1, wherein the inward extending stator poles comprise a plurality of layers normal to the toroidal stator and evenly spaced apart from each other.

6. The generator of claim 5, wherein the plurality of layers are spaced apart by air.

7. The generator of claim 5, wherein the plurality of layers are spaced apart by potting material.

8. The generator of claim 1, wherein the coil of wire comprises a steel interior surrounded by a copper coating, further surrounded by a gold, a silver or a nickel coating.

9. The generator of claim 1, wherein the coil of wire is enclosed in PEEK.

10. The generator of claim 1, wherein the coil of wire is potted within the interior channel.

11. The generator of claim 1, wherein the plurality of magnets are permanent magnets.

12. The generator of claim 1, wherein the plurality of magnets comprise two series of magnets disposed proximate mating stator poles on opposing sides of the interior channel.

13. The generator of claim 12, wherein mating magnets of the plurality of magnets corresponding with mating stator poles comprise opposite polarity.

14. The generator of claim 1, wherein adjacent magnets of the plurality of magnets comprise opposite polarity.

15. The generator of claim 1, wherein the rotatable conduit is rotated by a turbine.

16. The generator of claim 1, wherein the openings channel the fluid flow after the fluid flow passes a turbine.

17. A method of converting rotational energy into electrical energy, comprising:

providing a toroidal stator comprising an interior channel formed between inward extending stator poles and a coil of wire disposed within the interior channel;

rotating a plurality of magnets disposed proximate each stator pole around a central axis shared by the toroidal stator, coil of wire and plurality of magnets; and

channeling a drilling fluid into a rotatable conduit after the drilling fluid passes a turbine;

wherein the rotating the plurality of magnets comprises passing the drilling fluid past the turbine that rotates the rotatable conduit that secures the plurality of magnets proximate each stator pole.