1. Field of the Invention
The present invention relates generally to power supplies for generating high voltages. More particularly, the present invention relates to a high voltage power supply such as used with neutron generating tubes in oil well logging equipment. Further, the invention relates to the high voltage step up transformer required in such power supplies.
2. Related Art
Oil well logging devices which include neutron generating tubes are well known in the art. Such devices are sized to be lowered down an oil well bore and emit neutrons into the formation through which the bore passes. By detecting the radiation coming back from the formation, particularly the atoms in the formation that have been made radioactive by the emitted neutrons, the location of the oil bearing strata can be determined along the depth of the well. This return radiation indicates where the well casing should be perforated to allow oil to flow into the well.
The neutron generating tubes, which are the heart of these logging devices, require 100,000 volts, or more, to operate. Currently available logging devices generally use a Cockroft-Walton type voltage multiplier circuit which includes capacitors and rectifiers, which take an AC voltage from a high voltage step up transformer and converts it to a high DC voltage by successively raising up the voltage in a step wise fashion to operate the neutron generating tube. Voltage multiplying circuits using capacitors and rectifiers are well known, with the Cockroft-Walton series multiplier type circuit being commonly used in the currently available logging devices. To generate the required DC voltage needed by the neutron tube, the AC output voltage of the step-up transformer depends upon the number of stages utilized in the voltage multiplier, with 10 kV peak to peak being an average value among commonly available logging tools. To generate this high AC voltage within a working diameter of 1.25 inches (3.18 cm) is no easy task, especially with the fact that coaxial signal sensing conductors from the voltage multiplier must be run past the high voltage transformer assembly. This allows little room for dielectric insulation between the high voltage secondary windings and the magnetic core structure of the transformer, usually a ferrite material (which is conductive to high voltage). To further complicate the situation, these logging tools must be run at high underground temperatures, sometimes inside of a high-pressure housing. Many of the deep oil wells currently being drilled have internal temperatures in the deeper parts of the well over 150 degrees C. and up to 175 degrees C. or greater. This presents a problem in logging the deeper portions of the wells because, as indicated, the high voltage transformer must step up the incoming voltage with a limited amount of cross sectional area allotment, consequently this component is usually the least reliable of all devices in the 100 kV power supply. Therefore the presently used logging devices do not operate satisfactorily at extreme temperatures. Another problem often encountered is the operation of the ferrite transformer inside of a metal enclosure. If the ferrite is composed of two parts, such as in a high voltage C core configuration, the gap at the interface may leak magnetic flux into the pipe structure, causing excessive eddy currents which increase the loss of the power converter.
To offset this situation, some manufacturers decrease the high voltage output from the step up transformer and compensate by increasing the number of stages of the voltage multiplier circuitry. Unfortunately, there is a reasonable limit on the number of multiplying stages that can be used in a Cockroft-Walton series voltage multiplying circuit. Several reasons exist for this limit. One deals with the output voltage droop that occurs between no load and full load conditions which is proportional to the cube of the number of stages utilized. When the neutron tube is gated to be on, it is not uncommon to find the 100 kV dropping towards 80 kV as the power supply tries to feed into the load of the tube. A second problem that occurs when the number of stages is increased is the increase of AC ripple voltage that rides on the high voltage DC output due to the incomplete conversion of alternating to direct voltage. This unwanted electrical noise interferes with the acceleration voltage of the tube and is difficult to remove from the process. Unfortunately, the ripple voltage present on the high voltage output is proportional to the square of the number of stages used in the multiplier. It would be better if a reliable high voltage transformer can be devised which can be operated in excess of 10,000 VAC peak to peak at frequencies above 20 kHz.
As oil wells go deeper in their attempt to locate new sources of petroleum, the need will increase for neutron generating oil well logging equipment that are capable of operating at even higher temperatures, such as temperatures above 175 degrees C.
A high voltage step-up transformer includes an internal cylindrical core with internal through hole. The high voltage step-up transformer further includes a linear primary winding. The high voltage step-up transformer further includes a linear scaled bobbin onto which a high voltage secondary winding has been wound. The high voltage step-up transformer further includes a gap integrated into the transformer design between the internal cylindrical core and the outer magnetic field shield. The high voltage step-up transformer further includes a cylindrical outer magnetic field shield.
The internal cylindrical core can be a magnetic ferrite core with the internal through hole sized for passing signal wires there through. The internal cylindrical core can includes a magnetic metal-glass alloy core with internal through hole sized for passing signal wires there through. The linear primary winding can include a layer wound with turns side by side. The high voltage secondary winding can be wound in notches provided in the linear scaled bobbin to separate the individual sections. The cylindrical outer magnetic field shield can include a ferrite material. The cylindrical outer magnetic field shield can include a metal-glass alloy magnetic material. The cylindrical outer magnetic field shield can include a magnetic material. The cylindrical outer magnetic field shield can includes Permalloy. The internal cylindrical core can be positioned to allow signal pass through wires through the internal through hole.
The length of the cylindrical outer magnetic field shield can be at least 1.1 times as long as the length of the inner cylindrical core. The internal cylindrical magnetic material core with signal wire pass-through hole can include a powdered iron alloy material. The linear primary winding can include a one-layer primary winding of turns wound side by side and is constructed with a high temperature insulation wire. The linear scaled bobbin onto which the secondary has been wound can be constructed of a material with melting point above 125 degrees Celsius.
The bobbin diameter can be tapered to increase the dielectric spacing between the outer secondary wires and the magnetic shield.
The cylindrical outer magnetic field shield can be at least 1.1 times as long as the inner cylindrical core and can be composed of a ferrite material. The cylindrical outer magnetic field can be composed of a metal-glass alloy material. The cylindrical outer magnetic field shield can be composed of a nickel-iron alloy material.
As disclosed herein, ferrite cores are ideal for miniature step up high voltage transformers. Ferrite cores can be fabricated into practical shapes far more easily than silicon iron laminations, and in turn allow for less eddy current loss. Consequently, ferrite cores can be operated at much higher conversion frequency than iron lamination types, with a typical frequency in excess of 20 kHz. Most iron lamination high voltage transformers must be operated below 10 kHz—due to excessive eddy current and hysteresis losses. Operation at higher frequencies allows less droop in output voltage with less output ripple as well. Power supply designers who utilize ferrites in their high voltage transformer design can decrease the value of the multiplier capacitors used in the voltage multiplying section. It is therefore desirous to design neutron generating high voltage power supplies with ferrite material and take advantage of the improvement in volumetric efficiency as a result of higher frequency operation.
Using ferrites also increases the overall reliability of the converter because smaller value high voltage capacitors are inherently less likely to fail due to the decrease in plate area. While it is true that silicon iron lamination transformers enjoy a higher B field saturation flux density than ferrite devices by a factor of over three times, this is more than offset by the fact that they must be operated at lower frequencies as mentioned above. The only benefit that silicon iron transformers seem to have is their extremely high Curie point—the temperature where the relative permeability of the core material drops quickly towards zero. Values above 1000 degrees Celsius are quite common, which is certainly an advantage for high temperature power supply operation. The Curie point of manganese, or zinc ferrites, on the other hand are comparatively low, with values typically in the vicinity of 230 degrees Celsius. With careful design this handicap can be overcome by lowering the operational B field by increasing the number of turns placed on the transformer. Operation at values of one half the maximum saturation flux density (e.g. at 175 degrees C.) seem to be acceptable with respect to converter efficiency. This usually requires increasing both the primary and secondary turns of the transformer to higher values than one would normally use for room temperature designs.
1. Examples of Previous High Voltage Transformers and Problems Discovered by the Inventor Associated Thereto
As shown in
In well logging tools it is important to keep all of the magnetic flux within the core of the transformer design and not allow the magnetic flux to extend beyond the perimeter of the converter housing 105. If this happens, large eddy currents may be set up within the stainless steel pressure containment vessel that these devices are usually sealed in. If the AC magnetic field extends to the pressure vessel pipe, increases in input current to the converter will be noted causing more heat within the already hot device. The C, or even E, core designs suffer from this problem because the device is composed of two parts placed together with a gap between the mating halves. This gap is required to prevent saturation of the ferrites as a result of waveform imbalance. A gap is also required to increase the operating frequency of the device beyond 20 kHz.
One solution to this problem is to utilize a pot core type transformer 300 as shown in
2. Axial High Voltage Transformer with Signal Pass-Through Ability
The present invention includes a high voltage step up transformer offering a very high self-resonant frequency that is highly, or preferably completely, self-shielding in the radial direction. The high voltage step-up transformer can be used in any situation where a high voltage is needed. A specific application of the high voltage step-up transformer of the invention is in connection with oil well logging devices which are lowered down an oil well while emitting pulses of neutrons into the formation through which the well extends to find the oil bearing strata intersected by the well. The high voltage step up transformer is constructed with the axial mechanical constraints present in narrow bore down-hole applications in mind as highly advantageous applications, while other applications may also be applicable and highly advantageous as well. By suitable adjustment of primary and secondary winding ratio, the high voltage step up transformer can be utilized with any oscillatory input voltage to achieve the required step-up ratio. This transformer operates at a very high resonant frequency (e.g. f>80 kHz) due to its large magnetic field gap which is self-contained within the structure of the design itself. By utilizing a shielding outer ferrite core, the magnetic field is contained and will not reach out to the pressure vessel in which the power supply is mounted. Moreover, the design of this invention allows for easy signal wire pass through in the center of the device where the magnetic field is zero due to the inner ferrite core. Without having to run the signal wires from the output high voltage multiplier back along the outside of the transformer, the largest ferrite may extend to the inner diameter of the pressure vessel may be used. This increases both the electrical efficiency and the reliability of the step-up transformer which is important for high temperature operation as mentioned earlier.
An example embodiment described herein is shown in
Having a hole 440 in the central inner core 400 allows signal wires 445 from the high voltage multiplier section of the tool to be routed through and down to the control section of a power supply without the need to run the signal sires 445 about the outside of the outer ferrite shield 430. As such, the outer diameter of the outer ferrite shield can be increased such that to the entire inner diameter of the logging device's outer housing wall 450. For example, this inner diameter might be about 1.25 inches (3.18 cm), or less.
The internal cylindrical core 400 can be made from a magnetic metal-glass alloy core with internal through hole sized for passing signal wires there through. The linear primary winding 405 can be layer wound with turns side by side as shown. The high voltage secondary winding 415 can be wound in notches provided in the linear scaled bobbin 410 to separate the individual sections. The cylindrical outer magnetic field shield 430 can includes a ferrite material. The cylindrical outer magnetic field shield 430 can be composed of a metal-glass alloy magnetic material. The cylindrical outer magnetic field shield includes a magnetic material, such as Permalloy. The internal cylindrical magnetic material core with signal wire pass-through hole can include a powdered iron alloy material. And, the linear primary winding can include a one-layer primary winding of turns wound side by side and be constructed with a high temperature insulation wire. The linear scaled bobbin 410 onto which the secondary 415 has been wound can be constructed of a material with melting point above 125 degrees Celsius. The cylindrical outer magnetic field shield can be composed of a nickel-iron alloy material, for example.
3. Examples of Oil Logging Devices Within Which the Axial High Voltage Transformer with Signal Pass-Through Ability May be Used
Referring to
As indicated, the logging devices as shown in
As shown in
In the embodiments shown, the invention is directed to the high voltage transformer with signal wire pass-through ability. The other parts of the high voltage supply and the oil well logging device in which the high voltage supply and the voltage multiplier circuit of the invention is shown, as an example of its use as shown in
4. Tapered Bobbin for the Axial High Voltage Transformer with Signal Pass-Through Ability
As shown in
For example, in one working model the diameter of the first winding surface 605A can be 0.78 inches thick, the diameter of the second winding surface 605B can be 0.716 inches thick, and the diameter of the third winding surface 605C can be 0.668 inches thick. And, the diameters of the winding surfaces there between can gradually decrease accordingly.
Further, the distance between the winding surfaces can gradually increase or decrease along the length of the tapered bobbin. For example, referring to
For example, in the one working model previously discussed the first distance 610A can be 0.160 inches, the second distance can be 0.110 inches and the third distance can be 0.050 inches. And, the distances can gradually decrease across the length there between accordingly.
This application claims the benefit of, and priority to, U.S. Provisional Patent Application 61/480,164 filed on Apr. 28, 2011, the contents of which are hereby incorporated by reference herein.
Number | Date | Country | |
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61480164 | Apr 2011 | US |