System and method for downhole power generation using a direct drive permanent magnet machine
AssigneeNational Oilwell Varco, L.P.
InventorMicheal Albert Pridgeon
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Abstract
A system and method for generation of electrical energy by a downhole tool in a wellbore. A downhole tool for use in a wellbore includes a housing and a power generation system disposed within the housing. The power generation system includes a power section and an axial flux generator. The power section is configured to convert flow of drilling fluid through the downhole tool to rotation. The axial flux generator is coupled to the power section. The axial flux generator is configured to produce magnetic flux that extends parallel to an axis of the rotation, and to generate electrical energy responsive to the rotation.
Claims22
A downhole tool for use in a wellbore, comprising:
- a housing;
- and
- a power generation system disposed within the housing, the power generation system comprising:
- a power section configured to convert flow of drilling fluid through the downhole tool to rotation;
- and
- an axial flux generator coupled to the power section, the axial flux generator configured to:
- produce magnetic flux that extends parallel to an axis of the rotation;
- and
- generate electrical energy responsive to the rotation.
A method for generating power in a downhole tool used in a wellbore, comprising:
- pumping drilling fluid into a drill string disposed in the wellbore;
- converting movement of the drilling fluid through a power section disposed in the drill string into rotation of a shaft in the power section;
- rotating a rotor of an axial flux generator coupled to the shaft;
- generating magnetic flux parallel to an axis of rotation of the rotor;
- generating, via the magnetic flux, electrical energy in the axial flux generator responsive to the rotating.
A system for generating electrical energy downhole, comprising:
- an axial flux permanent magnet machine comprising:
- a plurality of disks arranged in a stack wherein a face of one of the disks is adjacent to a face of another of the disks;
- wherein at least one of the disks is a stator comprising a plurality of wire coils, and at least one of the disks is a rotor comprising a plurality of permanent magnets arranged in correspondence with the wire coils of an adjacent stator;
- a power section configured to rotate the rotor of the axial flux permanent magnet machine responsive to flow of drilling fluid through the power section;
- wherein rotation of the rotor by the power section generates the electrical energy in the coils.
Dependencies are inferred from the claim text.