HYDRAULIC PUMP WITH SOLID-STATE ACTUATOR

TECHNICAL FIELD

The present invention relates generally to controlling one or more of the flow rate and direction of a fluid, and more particularly to a hydraulic pump system.

BACKGROUND

The present disclosure relates to providing hydraulic power and, more particularly, to providing hydraulic power with a solid-state hydraulic pump that utilizes a solid-state actuator to drive a piston and thereby provide the force for volumetric displacement of fluid in a piston chamber.

In general, conventional hydraulic pumps may include a piston, a cylinder, and a pump chamber. The piston may reciprocate within the cylinder to compress or expand the volume of a pump chamber. One or more valves may provide for opening an inlet and an outlet of the pump chamber to allow fluid into the pump chamber in an expansion stroke of the piston and fluid out of the chamber in the compression stroke of the piston. A sealing member may be provided between the cylinder and the piston to prevent the fluid being pumped from leaking into the gap between the piston and the cylinder.

Conventional pumps often rely on a source of mechanical power such as a motor or an engine to provide the reciprocating movement to the piston. These conventional pumps have numerous rotating parts and have inherent inefficiencies. These conventional pumps also have a tendency to heat the fluids that they pump. These conventional pumps also need a large diameter for the windings and tend to be an inductive electrical load.

Traditionally, hydraulic pumps were used downhole to control flow rate of a downhole fluid which required a hydraulic line from the pump to the surface. Such systems are generally difficult to install and maintain as the lines can easily get plugged or incur build-up. Additionally, the response time of a hydraulic pump may not be instantaneous or may be delayed which increases inefficiencies in the system and reduces control over the flow rate of a downhole fluid.

It is desirable to provide a pump that has a reduced number of rotating parts, exhibits higher efficiencies, provides greater control over the flow rate of a downhole fluid and has a lower tendency to heat the fluids that it pumps.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present embodiments and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which like reference numbers indicate like features.

FIG. 1 is an illustration of a hydraulic pump, in accordance with certain embodiments of the present disclosure.

FIG. 2 is an illustration of a hydraulic pump, in accordance with certain embodiments of the present disclosure.

FIG. 3 is an illustration of a hydraulic pump system used to facilitate heat transfer, in accordance with certain embodiments of the present disclosure.

FIG. 4 is an illustration of a heat pump system, in accordance with certain embodiments of the present disclosure.

FIGS. 5A, 5B, and 5C are partial illustrations of a completely sealed hydraulic pump, in accordance with certain embodiments of the present disclosure.

FIG. 6 is an illustration of a solid-state hydraulic pump system, in accordance with one or more embodiments of the present disclosure.

FIG. 7 is an illustration of a solid-state hydraulic pump system deployed in a downhole tool in a well environment, in accordance with one or more embodiments of the present disclosure.

FIG. 8 is flowchart illustrating a method for controlling pumping of a fluid using a solid-state hydraulic pump, in accordance with one or more embodiments of the present disclosure.

While embodiments of this disclosure have been depicted and described and are defined by reference to exemplary embodiments of the disclosure, such references do not imply a limitation on the disclosure, and no such limitation is to be inferred. The subject matter disclosed is capable of considerable modification, alteration, and equivalents in form and function, as will occur to those skilled in the pertinent art and having the benefit of this disclosure. The depicted and described embodiments of this disclosure are examples only and are not exhaustive of the scope of the disclosure.

DETAILED DESCRIPTION

Additionally, the present disclosure relates to providing a solid-state hydraulic pump for the control of a flow rate of a target fluid, for example a downhole production fluid in a hydrocarbon recovery or production process or any other well fluid. For example, traditional downhole tools used for controlling flow rate of a production fluid (such as remote open close tool or ROCT) may be used to control flow rate of a target fluid. The traditional hydraulic system uses a hydraulic rotary pump, for example, a Leduc-style pump, as the electrohydraulic pump. This hydraulic rotary pump is generally effective and reliable but inherently requires a high power draw device. Also, the hydraulic rotary pump does not allow for precise control of flow rate as a threshold power is required for proper operation. Further, as the hydraulic rotary pump requires rotating parts and dynamic seals which may affect maintenance, replacement costs and reliability as compared to other types of pumps.

The use of a solid-state hydraulic pump that uses a piezoelectric stack, magnetostrictive element or electrostrictor element for driving a solid-state actuator may provide for increased reliability, efficiency and control over flow rate of a production or well fluid. Such a solid-state hydraulic pump may operate at higher frequencies as compared to the traditional hydraulic rotary pump which allows for an efficient pumping of a pump fluid such as a hydraulic fluid to open and close a flow restrictor, such as a ball valve, sliding sleeve, piston valve or any other type of flow regulator. This type of solid-state hydraulic pump may also utilize a power source that may be compact and may be completely located downhole, such as one or more batteries, flow harvester or other downhole power source.

Illustrative embodiments of the present disclosure are described in detail herein. In the interest of clarity, not all features of an actual implementation may be described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the specific implementation goals, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of the present disclosure.

To facilitate a better understanding of the present disclosure, the following examples of certain embodiments are given. In no way should the following examples be read to limit, or define, the scope of the disclosure. Embodiments of the present disclosure may be applicable to horizontal, vertical, deviated, or otherwise nonlinear wellbores in any type of subterranean formation. Embodiments may be applicable to injection wells as well as production wells, including hydrocarbon wells.

In certain embodiments according to the present disclosure, a solid-state material, such as a magnetostrictive material, may be used to provide movement to a piston that is fluidically coupled to a port. The port may include an inlet and/or an outlet. In certain embodiments, the solid-state material, piston, and port may be within a hydraulic pump. Magnetostrictive materials have the property that, when a magnetic field is applied to the material, a strain is induced in the material, causing a change in the linear dimensions. This strain and change in the linear dimensions of the material may cause movement to a piston within a hydraulic pump. A suitable material for the magnetostrictive material may be Terfenol-D, available from Etrema Products, Inc. Various materials, e.g., iron and iron alloys such as Terfenol, Galfenol, Metglas and Alperm as well as nickel and nickel allows, may provide suitable magnetostrictive and giant magnetostrictive responses. A magnetic field may be applied to these materials, e.g., by applying an electric current to a coil surrounding the material or to a loop anywhere else in the magnetic circuit.

FIG. 1 is an illustration of one example hydraulic pump comprising a solid-state material to actuate the hydraulic pump, in accordance with certain embodiments of the present disclosure.

As shown in FIG. 1, a hydraulic pump 100 may include body 101, a solid-state actuator 105, a drive electronics 110, a pump piston 115 in a cylinder 116 to compress or expand the volume of a pump chamber 117, a seal 120, phase balancing electronics 125, a power source 130, an inlet check valve 135, an outlet check valve 140, and ports which may include a low-pressure inlet 145 and a high-pressure outlet 150.

Drive electronics 110 may be coupled to a solid-state actuator 105. Drive electronics 110 may produce an electrical signal with an alternating current (AC) component or with a direct current (DC) signal component to drive the solid-state actuator 105. In one or more embodiments, the AC signal may have a frequency between 10 Hertz (Hz) and 100 kiloHertz (kHz). In one or more embodiments, the amplitude of the AC signal component is approximately equal to the amplitude of the DC signal component. The solid-state actuator 105 may comprise a piezoelectric or magnetostrictive material. The solid-state actuator 105 may be any suitable piezoelectric or magnetostrictive materials including any piezoceramic, piezoelectric, electrostrictive, ferroelectric, relaxor ferroelectric, or magnetostrictive material that that can be driven by an electrical or magnetic input and that provides a mechanical output in the form of a force or motion. When an electric or magnetic field is applied to such materials, the materials change shape in response to the applied field. These materials also usually respond to mechanical force or motion by generating an electric field which produces a voltage across its electrical connections, e.g., across electrodes, or a magnetic field which in turn may produce voltage across a conductor coiled around the materials. Generally, a piezoelectric material responds most strongly to an applied electric field. Generally, a magnetostrictive material responds most strongly to an applied magnetic field.

For purposes of the present disclosure, each solid-state actuator 105 is considered to have one or more electrical or magnetic connections and one or more mechanical connections. Each connection may be considered to be an input or an output or both, depending on whether the actuator is being used at the time to convert electrical energy into force or motion or to convert force or motion into electrical energy. As a result, the solid-state actuator 105 comprising such materials may be used as an actuator and as a sensor. The solid-state actuator 105 may comprise the piezoelectric or magnetostrictive material in the form of a stack, a series of thin plates stacked and wired electrically in parallel. The piezoelectric or magnetostrictive material may also possess a polycrystalline, single crystal, or amorphous structure.

As shown in FIG. 1, the drive electronics 110 may be coupled to the solid-state actuator 105. The drive electronics 110 may include an insulated conductor and may be in electrical connection with the power source 130. In certain embodiments, as shown in FIG. 1, the balancing electronics 125 may also be in electrical connection with the power source 130 and the drive electronics 110. In certain embodiments, the balancing electronics 125 may include a capacitor. In other embodiments, the balancing electronics 125 may include an inductor. In certain embodiments, the balancing electronics 125 may be used to balance the electrical reactance, for example, capacitance or inductance, of the solid-state actuator 105 and drive electronics 110. In certain embodiments, the balancing electronics 125 may be used to create an electrical resonance. In certain embodiments, the electrical resonance is near the mechanical resonance of the system.

In certain embodiments, a shape change in the solid-state actuator 105 may be induced by applying and/or varying a voltage across the drive electronics 110. The shape change of the piezoelectric or magneto strictive materials may be controlled by the application of electric or magnetic fields. It should be appreciated that the shape may be controlled in various ways in various embodiments, for example, by using alternative means to vary a magnetic field, such as with a permanent magnet or electromagnet.

In one non-limiting example, a shape change or strain of 0.5% may occur along the long axis of the stack. It should be understood that the shape change or strain may be greater or less than 0.5% with various embodiments. In some embodiments, a small strain such as 0.5% may displace the cross-sectional area of the stack resulting in a net volume change when measured along the primary stack axis. Such shape change may be used to pressurize and pump a fluid in certain embodiments.

In certain embodiments, the hydraulic pump 100 may use the solid-state actuator 105 to provide hydraulic pressure. As shown in FIG. 1, the hydraulic pump 100 may comprise the piston 115. The shape changed induced in the solid-state actuator 105 may move the piston up and down, forcing fluid flow from the low-pressure inlet 145 to the high-pressure outlet 150.

The hydraulic pump 100 may further include the inlet check valve 135 and the outlet check valve 140. In some embodiments, the inlet check valve 135 and the outlet check valve 140 may rectify the flow and create a steady flow passage from the low-pressure inlet 145 to the high-pressure outlet 150. In certain embodiments, the inlet check valve 135 and the outlet check valve 140 may comprise reed valves. In other embodiments, a compact system of valves may be needed to rectify the high frequency reciprocating pump output. In some embodiments, simple and compact valves may be used for this purpose. In other embodiments, separate sets of valves may act as check valves. In other embodiments, the valves may be powered by their own solid-state actuators.

The hydraulic pump 100 may further comprise the seal 120. The seal 120 may comprise a seal or a flexure. In some embodiments, the seal 120 may form a seal around the piston 115 to ensure that no fluids come into contact with the solid-state actuator 105. In some embodiments, the seal 120 may be a ring. In some embodiments, the seal 120 may be a baffle. In some embodiments, the seal 120 may comprise an elastomer, a plastic, a metal, a ceramic, or glass.

In some embodiments, each cycle of the pump 100 displaces an amount of fluid proportional to the strain induced in the solid-state actuator 105. In certain cases, the total fluid flow is proportional to the fluid displaced in each cycle and frequency of reciprocation. In one or more embodiments, inlet check valve 135 and outlet check valve 140 may operate at low frequency of less than one Hertz and can also operate at higher frequencies of several hundred thousand Hertz.

In certain embodiments, the hydraulic pumps of the present disclosure may be capable of high-pressure operation with low flow rates. In some embodiments, effective generation of fluid power requires that the hydraulic pumps of the present disclosure operate at a substantial bias pressure. In some embodiments, for pump applications where occasional access is possible, the bias pressure can be set once and then it can be monitored and even adjusted if needed. In other embodiments, such as remote installations, adjustment may be done by different means. In particular, in some embodiments, an accumulator and charge system may function well, but a bootstrapping bias pressurization may be an appropriate secondary method. Bootstrapping may involve additional valves and can be demonstrated to reliably elevate system pressure, but the additional valves require volume and increase the number of components. In one or more embodiments, the bias pressure may be provided by the hydrostatic pressure of the wellbore.

FIG. 2 is an illustration of a hydraulic pump comprising an arrangement of piston assemblies, in accordance with certain embodiments of the present disclosure. In certain embodiments, a hydraulic pump 200 may comprise a pump body 101 (as shown in FIG. 1), one or more solid-state actuators 105, one or more pistons 115 in one or more cylinders 116 to compress or expand the volume of a pump chamber 117, one or more seals 120, an inlet check valve 135, an outlet check valve 140, a low-pressure inlet 145, and a high-pressure outlet 150. In certain embodiments, the arrangement of piston assemblies may be connected in parallel in the fluid circuit. In certain embodiments, the arrangement of piston assemblies may be electrically driven together in either parallel or series circuit. In some embodiments, an arrangement of piston assemblies provides for more fluid movement per cycle. An increase in fluid movement per cycle may help to overcome the leakiness and the fluidic backlash in the check valves. The arrangement of piston assemblies may have a combination of solid-state actuators that have different electrical loads. A solid-state actuator with a capacitive load (i.e., piezoelectric) may be combined with a solid-state actuator with an inductive load (i.e., magnetostrictor) to create a balanced electric load. A check valve may be located between the plurality of piston assemblies in case the different piston assemblies are not being driven in phase. Other parts may be in between the piston assemblies, such as a thermal radiator or a hydraulic accumulator.

FIG. 3 is an illustration of a hydraulic pump system that may be used to facilitate heat transfer, in accordance with certain embodiments of the present disclosure. As shown in FIG. 3, a hydraulic pump 300 may pass fluid through one or more radiators 310, over a circuit board 320, and through one or more radiators 310. Elements in the system may be fluidically coupled with a conduit assembly, which may include any suitable connections, piping, tubing, hose, etc. As depicted, the hydraulic pump system may be a closed-loop system. The fluid passed over the circuit board 320 may absorb heat generated from the circuit board 320 and radiate the heat to the environment through the one or more radiators 310. A radiator 310 may be any suitable heat exchanger to receive the fluid and transfer heat from the fluid passing therethrough to an exterior area adjacent to the radiator. In some embodiments, the hydraulic pump 300 may comprise each of the same components included in the hydraulic pump 100 discussed above with respect to FIG. 1. In certain embodiments, the hydraulic pump 300 may need less pressure but operates at increased flow rates than conventional pumps. In other embodiments, the hydraulic pump 300 operates with a higher efficiency than conventional pumps. In other embodiments, the hydraulic pump 300 may pass fluid through conduits created on the surface of the circuit board 320 or on the interior of the circuit board 320.

FIG. 4 is an illustration of a heat pump system, in accordance with certain embodiments of the present disclosure. As shown in FIG. 4, a hydraulic pump 400 may pass fluid through one or more radiators 410, through one or more expansion valves 420, and over one or more electronics 430. Elements in the system may be fluidically coupled with a conduit assembly, and the hydraulic pump system may be a closed-loop system, similar to the system of FIG. 3. In some embodiments, the hydraulic pump 400 may comprise each of the same components included in the hydraulic pump 100 discussed above with respect to FIG. 1.

In certain embodiments, the hydraulic pump 400 may heat the fluid when it compresses the fluid. In certain embodiments, the fluid may then be cooled when it passes through the radiator 410. Additionally, in certain embodiments, the one or more expansion valves 420 may allow the fluid to expand and further cool. The fluid may then pass over the one or more electronics 420 and absorb heat.

In certain embodiments, a hydraulic pump according to the present disclosure may be employed to charge a hydraulic accumulator. The stored hydraulic energy in the accumulator may be used for any suitable downhole purpose. For example, the energy stored in the hydraulic accumulator may be used to move a downstream valve, piston, sliding side door, etc. Using the example of FIG. 4, the hydraulic pump 400 may be coupled to a hydraulic accumulator in lieu of the radiator 410 shown. And, instead of the downstream components 420, 430 depicted in FIG. 4, any suitable downstream components may be coupled in fluidic communication with upstream accumulator.

Referring again to the example of FIG. 1, the hydraulic pump 100 may be provided with control electronics 128. The control electronics 128 may include phase balancing electronics 125 or may be provided separately. Though not shown, control electronic 128 also may be provided with any of the embodiments illustrated in FIGS. 2-4. In certain embodiments, control electronics 128 (which may include, e.g., a microprocessor) may be configured to drive the pump to provide flow control and/or provide pressure control. By way of non-limiting example, the flow control may be provided by controlling a frequency of excitation; the pressure control may be provided by controlling drive amplitude and/or by controlling excitation. In certain embodiments, generic digital control may be provided from memory and/or an outside controller to provide programmable arbitrary flow control and/or pressure control. In certain embodiments, digital control may be tied to temperature, pressure, flow, and/or another hydraulic pump used in a sense mode. Certain embodiments may be configured to have the capability to duplicate pressure and/or flow of coupled hydraulic and may thereby act as a hydraulic amplifier.

Control electronic 128 also may be provided to two or more pumps. In certain embodiments, a plurality of pumps may be coupled and configured to operate generally synchronously. The plurality of pumps may operate mutually out of phase to reduce ripple. A plurality of pumps or sets of pumps may be controlled to operate one set to provide a gross setting (possibly using a physically larger, optimized pump) and other sets to trim/fine tune. In one or more embodiments, one pump may be used to push the fluid in one direction (for example, to open a vale) and a second pump may be used to push the fluid in a second direction (for example, to close a valve).

Certain embodiments may include a plurality of pumps (or sets of pumps). In certain embodiments, one pump or set of pumps may provide a gross setting, with another providing constructive flow/pressure, and with a third that is reversed to provide destructive flow/pressure to provide for greater gross setting and additional trimming/fine tuning. An accumulator also may be provided to further decrease ripple. For an optional ability to control the solid-state actuator, electronics (with one or more controller(s), memory, drive circuitry, electronic communication interface) can be used with a variety of sensors (including this invention) to measure pressure, flow, displacement, etc., in and/or out).

FIGS. 5A, 5B, and 5C are partial illustrations of a completely sealed hydraulic pump 500, in accordance with certain embodiments of the present disclosure. The hydraulic pump 500 may include certain elements previously disclosed herein, such as a pump body 101, a solid-state actuator 105, an electronics device 110, a pump piston 115, and a port that may include a high-pressure outlet 150. However, the hydraulic pump 500 eliminates seals in operation to eliminate the potential for system leaks in conventional pumps, which may leak either in control elements (check valves, solenoids, etc.) and/or between the oil volume and the exterior. Thus, the hydraulic pump 500 may be useful in a variety of applications including but not limited to opening and closing a valve or manipulating the amount of fluid restriction in a flow passageway. Using any suitable method, the hydraulic section may be closed off so that the assembly would be virtually free of moving parts, wear and contaminant creation, contaminant ingress and, properly designed immune to pressure. In various embodiments, suitable methods may include but not be limited to metal-to-metal-seals, weldments, compression fittings, possibly welded closed, etc. As depicted in FIG. 5A, the hydraulic pump 500 may include a bellows 510 coupled to the piston 115 on the outlet side for the production of output pressure in conjunction with actuation of the piston 115. In certain embodiments, a spring 505 disposed between the piston 115 and the pump body 101 may provide resiliency for the piston cycle.

FIGS. 5B and 5C illustrate alternative embodiments of the hydraulic pump 500. Instead of including the piston 115, bellows 510, and spring 505 configuration, the solid-state actuator 105 may be configured to directly actuate a compliant element 520 (FIG. 5B) or a diaphragm 525 (FIG. 5C). The compliant element 520 may be any suitable compliant body with a shape and resilient material in the non-limiting example depicted. The solid-state actuator 105 is configured to directly contact a convex side of the compliant element 520. Likewise, the diaphragm 525 may be any suitable bellows-type element with a shape and resilient material to provide an output pressure to the outlet 150 upon actuation of the solid-state actuator 105 and a return force upon relaxation of the solid-state actuator 105.

While the hydraulic pump 500 is depicted by way of examples without limitation in FIGS. 5A-5C as each including a single assembly for the solid-state actuator 105, certain embodiments may include a plurality of the solid-state actuators 105. Any number of the solid-state actuators 105 of may work on the pump piston 115, the compliant element 520, or other suitable surface to provide added power, force, and displacement. As a non-limiting example, a plurality of the solid-state actuators 105 on the order of thousands, tens of thousands, or more, may work in conjunction on one or more suitable surfaces, and, for example, may be on a nanometric scale. Additionally, certain embodiments may be implemented in medical applications, with, for example, the solid-state actuators 105 configured to mimic the peristatic motion of the esophagus, the motion of the diaphragm, bowels, heart, etc.

FIG. 6 is an illustration of one example solid-state hydraulic pump system 600 comprising a solid-state material to actuate the solid-state hydraulic pump 610, in accordance with one or more embodiments of the present disclosure. The solid-state hydraulic pump system 600 may comprise one or more tools, modules or devices including, but not limited to, any one or more tools, components, devices, or modules of FIGS. 1-5C. In one or more embodiments, the solid-state hydraulic pump system 600 comprises an electronics module 602a, a solid-state hydraulic pump assembly 602b, an expansion chamber 602c and a valve mechanism 602d. A solid-state hydraulic pump system 600 may comprise a single device, tool, for example, a downhole tool, or a plurality of devices or tools coupled together, for example, via a connector or coupler (not shown). For example, each module or device 602a, 602b, 602c and 602d may comprise a separate tool, a single tool or any combination of one or more tools. In one or more embodiments, solid-state pump system 600 is disposed in one or more downhole tools.

Electronics module 602a may comprise a power source 630, one or more power lines, for example, 606a and 606b (collectively, power lines 606), one or more signal lines, for example, signal line 608, and a communications port 604. Communications port 604 may receive information from and transmit information to an information handling system 618 at the surface or other computing device. For example, the electronics module 602a may receive a control signal 654 via the communications port 604. The communications port 604 may be coupled to the power source 630 directly or indirectly via a wired or wireless connection 622. The power source 630 may provide different power levels to the power lines 606. The communications port 604 may communicate the control signal 654 or information associated with the control signal 654 to the power source 630 to set, adjust, or otherwise alter the power level including changing the frequency, amplitude, duty cycle, or both of the power source 630 to control the power supplied to one or more modules, devices or other components of the solid-state hydraulic pump system 600. In one or more embodiments, power source 630 may be a self-contained or self-generating power source within electronics module 602a. For example, power source 630 may comprise a battery, a flow harvester, such as a turbine, any other suitable power source or any combination thereof. In one or more embodiments, power source 630 may be coupled or otherwise connected to a power source at the surface. The power source 630 may operate at a high frequency which allows efficient pumping of a pump fluid, for example, hydraulic fluid, to open and close a flow restrictor valve, for example, one or more flow restrictor valves 626a and 626b, collectively 626, of valve mechanism 602d. Opening and closing a flow restrictor valve 626 allows for controlling the amount of fluid that is produced from one or more different zones within a wellbore. Opening and closing a flow restrictor valve 626 also restricts flow from any one or more zones within a wellbore that are producing an unwanted fluid, such as water, and minimizing the flow restriction from any one or more other zones within the wellbore that are producing a desired fluid, such as a hydrocarbon.

One or more power lines 606 may couple to one or more modules or devices. The one or more power lines 606 may comprise one or more lines, wires, cables, any other suitable transmission material or any combination thereof. In one or more embodiments, power line 606b may couple to a solid-state hydraulic pump 610. In one or more embodiments, power line 606a may couple to a diverter assembly 614. In one or more embodiments, power lines 606a and 606b may comprise a single power line or a plurality of power lines with a splitter or connector that allows for power to be directed to a plurality of devices, components, tools, any other downhole equipment or any combination thereof.

The solid-state hydraulic pump assembly 602b may comprise a solid-state hydraulic pump 610, a diverter block 612 and a diverter assembly 614. Solid-state hydraulic pump 610 may comprise a pump motor 632 coupled to a pump gearbox 634. Solid-state hydraulic pump 610 may couple to a diverter block 612. Diverter block 612 may couple to a diverter assembly 614. Diverter assembly 614 may comprise a diverter cylinder motor 636 coupled to a diverter cylinder gearbox 638. The diverter assembly 614 may comprise one or more diverter ports, for example, diverter ports 640a, 640b and 640c (collectively, one or more diverter ports 640) fluidically coupled to one or more fluid flow lines, for example, fluid flow lines 642a, 642b, 642c (collectively, one or more fluid flow lines 640), respectively. The one or more fluid flow lines 640 may comprise a fluid, for example, hydraulic fluid. At least one of the one or more fluid flow lines 640 may couple to an expansion chamber 602c, for example, fluid flow line 642c may be coupled to expansion chamber 602c at a connector 644. At least one of the one or more fluid flow lines 642 may couple to valve mechanism 602d, for example, fluid flow lines 642a and 642b. The diverter block 612 and diverter assembly 614 allow a change in direction of pumping such that the one or more fluid flow lines 642 allow for bidirectional fluid flow. For example, in one or more embodiments fluid in the one or more fluid flow lines 642 may be pumped in either direction.

Expansion chamber 602c may comprise a fluid reservoir 616, pressure transducer 646, one or more pressure ports, for example, pressure ports 648a, 648b, 648c (collectively, one or more pressure ports 648). The fluid reservoir 616 may comprise a fluid, for example, hydraulic fluid 650, and may fluidically couple via one or more fluid flow lines 642c to the solid-state hydraulic pump assembly 602b. The one or more pressure ports 648 may fluidically couple to one or more pressure lines, for example, pressure lines 624a, 624b and 624c, collectively pressure lines 624. In one or more embodiments, pressure line 624a may couple pressure port 648a to valve port 652a, pressure line 624b may couple pressure port 648b to valve port 652b and pressure line 624c may couple pressure port 648c to valve port 652c. In one or more embodiments, pressure transducer 646 may communicate or otherwise transmit a signal indicative of pressure, for example, hydraulic pressure, via signal line 608 coupled to a pressure signal port 620. Signal line 608 may be coupled to electronics module 602a either via a wired connection, including but not limited to, a line, a cable, a wire or via a wireless connection. In one or more embodiments, the pressure signal communicated via signal line 608 is transmitted from the electronics module 602a to an information handling system 618 at the surface or downhole via the communications port 604. In one or more embodiments, the signal line 608 is within a tubing string or an annulus of a tubing string (not shown). In one or more embodiments, the electronics module 602a or information handling system 618 may alter or otherwise adjust frequency, amplitude, or duty cycle as a means of adjusting the level of power of the power source 630 based, at least in part on the pressure signal communicated via signal line 608. The opening, closing or rate of opening and closing of any one or more valves 626 of valve mechanism 602d may be based, at least in part, on the pressure signal of signal line 608.

Valve mechanism 602d may comprise a ball valve, a sliding sleeve, a piston valve or any other flow regulator. In one or more embodiments, valve mechanism 602d may comprise one or more flow restrictor valves, for example, flow restrictor valves 626a and 626b (collectively, one or more flow restrictor valves 626). A fluid, for example, hydraulic fluid 650 or any other suitable pressurized fluid, may flow between the valve mechanism 602d and the solid-state hydraulic pump assembly 602b via pressure lines 624 to transition the one or more flow restrictor valves 626 to a position, for example, from an open to a closed positioned, from a closed position to an open position or any position in between.

FIG. 7 is an illustration of a solid-state hydraulic pump system deployed in a downhole tool in a well environment 700, in accordance with one or more embodiments of the present disclosure. A downhole tool 710 may be deployed in a borehole or well bore 720 of a formation 730. The downhole tool 710 may comprise a solid-state hydraulic pump system 600 according to FIG. 6 or any other solid-state hydraulic pump system discussed above. In one or more embodiments, downhole tool 710 may comprise one or more downhole tools and solid-state hydraulic pump system 600 may be disposed or positioned within any one or more of the one or more downhole tools 710. The borehole 720 may comprise a production fluid or other well fluid 740.

FIG. 8 is a flowchart illustrating a method for controlling pumping of a fluid using a solid-state hydraulic pump, in accordance with one or more embodiments of the present disclosure. At step 802 a tool comprising a solid-state hydraulic pump system 600 of FIG. 6 is deployed. For example, as illustrated in well environment 700 of FIG. 7, a downhole tool 710 that comprises a solid-state hydraulic pump system 600 may be deployed in a borehole 720.

At step 804, a control signal or command (for example, control signal 654 of FIG. 6) is sent to the power source 630 of the solid-state hydraulic pump system 600 via communications port 604 of electronics module 602a as illustrated in FIG. 6. The control signal or command sets the output of the power source 630. The power source 630 outputs or generates power based on the signal or command. At step 806, the solid-state hydraulic pump 610 of FIG. 6 is actuated based, at least in part, on the power supplied via power line 606a of FIG. 6. In one embodiment, the solid-state hydraulic pump 610 can be actuated at a level that utilizes all the supplied power. In another embodiment, the pump actuation adjustments may be limited to protect components when the supplied power adjusts at a rate above a certain level.

At step 808, the solid-state hydraulic pump 610 is actuated such that the flow rate of a pump fluid, for example, a hydraulic fluid 650 of FIG. 6, drawn or pumped in from fluid reservoir 616 of FIG. 6 is altered or adjusted based, at least in part, on the actuation of the solid-state hydraulic pump 610. At step 810, the solid-state hydraulic pump 610 is actuated such that the flow rate of the fluid pumped out from the solid-state hydraulic pump assembly 602b of FIG. 6 is altered or adjusted based, at least in part, on the actuation of the solid-state hydraulic pump 610.

At step 812, one or more flow restrictor valves 626 of valve mechanism 602d of FIG. 6 are altered or adjusted based, at least in part, on the actuation of the solid-state hydraulic pump 610. For example, one or more of the one or more flow restrictor valves 626 may be transitioned from an open position to a closed position, from a closed position to an open position or anywhere in between. As the solid-state hydraulic pump is controlled by a high frequency power source, the actuation of the solid-state hydraulic pump 610 and the one or more flow restrictor valves 626 may be controlled more precisely than using traditional hydraulic pumping systems. In one embodiment, each cycle of the power source only moves a small amount of the desired volume of liquid through the pump such that it would take many cycles in order to achieve the desired fluid displacement. In such an embodiment, the system can include a high-frequency power source that produces more cycles in a particular period of time. In such an embodiment, the amount of fluid moved can be determined based on a count of the number of cycles that the controller has imparted on the actuator.

At step 814, a production fluid or other well fluid 740 of FIG. 7 is pumped to the surface 702 or out of the borehole 720. The flow rate of the pumping of the production fluid 740 may be based, at least in part, on the actuation of the solid-state hydraulic pump 610.

Therefore, the present disclosure is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. The indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the element that that a particular article introduces; and subsequent use of the definite article “the” is not intended to negate that meaning.

	Number	Date	Country
Parent	14002797	Sep 2013	US
Child	15825765		US

HYDRAULIC PUMP WITH SOLID-STATE ACTUATOR

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CPC

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