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11859398 | DETAILED DESCRIPTION Embodiments of the present invention provide a portable post office configured to be employed as a single unit and contained entirely within an intermodal shipping container. Such structures may be configured to be deployed in an area where postal services have been interrupted, such as after a natural disaster that destroyed or damaged a local post office and/or multiple delivery addresses. Such structures may be configured to be readied for use with minimal labor and no extra construction materials. Thus, in certain embodiments, after placement at the desired location, the intermodal container doors may be opened to reveal an entryway into the portable post office. Said entrance may be made primarily of glass or other such transparent or translucent material to allow natural light into the structure, and to allow the interior to be viewed from the exterior. With the floor of intermodal container being approximately six inches off the ground, certain embodiments may further include a landing attached to the exterior of the entrance, and an accessibility ramp attached to said landing as to allow a wheeled device or vehicle to enter the portable post office through the entrance. When not in use, such as during transport, said landing and said accessibility ramp may be stored inside of the portable post office in the center aisle. The interior of certain embodiments of the present invention may include a center aisle flanked by one or more rack members against the left side and right side walls. Each of the one or more rack members may be movably secured to a track member mounted to the ceiling of the portable post office via a trolley or other such rolling device configured to allow said rack member to be moved along said track member. Said track member may be mounted perpendicular to said left side and right side walls such that a rack member movably secured to said track member may be moved into the center aisle. Each rack member may be configured to hold a plurality of p.o. boxes, each having a lockable door of facing the center aisle, and an open end opposite said lockable door. Said p.o. boxes may be provided with certain embodiments of the present invention, or p.o. boxes from a damaged local post office may be moved into said rack members upon deployment of the structure. A user may enter the portable post office via the entrance, which opens into the center aisle. The user may then locate the appropriate p.o. box and access the contents therein via the corresponding lockable door. During normal operation of the portable post office, said rack member may be secured against the left side or right side walls via a locking mechanism such that the open sides of the p.o. boxes cannot be accessed. When mail is delivered, an authorized user, such as a postal worker, may unlock the locking mechanism and move one or more rack members into the central aisle along the track member to which it is movably secured, such that said authorized user may then access the open sides of the p.o. boxes via the rear of the rack member for the purpose of delivering mail to said p.o. boxes without having to unlock each individual p.o. box. Because certain embodiments of the present invention may be deployed into areas where other services, such as electricity, may have been interrupted or are otherwise not available, some embodiments may further include a power system configured to supply electricity to such features as interior lighting, air conditioning, and/or one or more interior electrical outlets. Such a power system may be configured to receive electricity from a primary power supply, which may be a solar panel, which may be mounted to the roof of the intermodal container, a portable electric generator positioned nearby the portable post office, or from local electrical services, should such service be available. Said power system may further include a power converter configured to convert electricity received from the aforementioned sources into the voltages and AC frequencies appropriate for such features as an air conditioner, interior lighting, or an interior electrical outlet. For example, said power converter may be configured to allow a 220 volt air conditioner to be power from a 110 volt generator. Said power system may further include one or more rechargeable battery packs configured to deliver electricity to said features when the primary power supply is not available. FIG.1,FIG.2A, andFIG.2Bare a front perspective view, a front view, and a top view, respectively, of portable post office100, according to an exemplary embodiment of the present invention. Post office100may be entirely contained within intermodal container105having container doors110at one end of said container. Users may enter post office100via entrance115, which may be made of glass or other transparent or translucent material to allow natural light and visibility into portable post office100. In certain embodiments, entrance115may be a single door, a double door, and may include sidelights. When it is desirable to protect entrance115from damage, such as during transport or when post office100is not in use, container doors110may be closed and secured. Landing120and accessibility ramp125may be installed adjacent to entrance115upon deployment of post office100and are configured to allow a wheeled device, such as a wheelchair, to enter post office100through entrance115. Landing120and ramp125may be made of aluminum, steel, or other suitable material, and may be configured to be stored within container105when not in use, such as during transport. Certain embodiments of the present invention may also include an air conditioner having condenser130, which may be configured to draw in external air via an air intake and to deliver cool air to the interior of the post office100via an evaporator/vent located within the structure. Said air conditioner may receive electricity from a power system supplied by solar panel135. Said power system may be further configured to deliver electricity to other internal components, such as lighting and an electrical outlet. FIG.3is a front view of the interior of a portable post office300contained inside an intermodal container, according to an exemplary embodiment of the present invention. The interior of post office300may have center aisle305, with one or more rack members310against the left side and right side walls of post office300. Each rack member310may be configured to hold a plurality of p.o. boxes315positioned such that the lockable door of each p.o. box315faces center aisle305. Each rack member310may be movably secured to one or more track members320via a trolley and configured such that rack member310may be moved along the one or more track members320into center aisle305. Certain embodiments of the present invention may further include a power system, which may include rechargeable backup batteries325. Said power system may be configured to supply electricity to interior lights330, and an air conditioner having vent335. Some embodiments of the present invention may include a landing adjacent to the entrance to post office300, as well as an accessibility ramp affixed to said landing as to provide a way for wheeled devices, such as a wheel chair, to access the interior of post office300. When not in use, such as during transportation, said landing and ramp may be configured to be stored in center aisle305until needed. FIG.4Ais a left side view of the interior of a portable post office400, andFIG.4Bis a right side view of the interior of a portable post office400, according to an exemplary embodiment of the present invention. Each of the left side and the right side of post office400may have one or more rack members405configured to hold a plurality of p.o. boxes410. P.O. boxes410may be all of a uniform size, or may be different sizes to accommodate different sizes of mail or packages, depending on the needs of the p.o. box users. Each of the one or more rack members405may be secured to the left side wall or the right side wall by locking mechanism415. Locking mechanism415may include a horizontal member420movably secured to either said left side wall or said right side wall and configured to slide horizontally against said side wall into a first position and a second position. Locking mechanism415may further include a handle member425by which a user may slide member420horizontally against said left side wall or said right side wall into said first position and said second position. In said first position, a hook member positioned on horizontal member420may be configured to engage with a loop member on the rear of rack member405such that rack member405is secured against the side wall to which horizontal member420is movably secured. In said second position, said hook member may disengage from said loop member. Said locking mechanism415may also include lock430, which may be configured to secure said locking mechanism415in place, thereby preventing a user from sliding horizontal member420. FIG.5is a front perspective view of the interior of a portable post office500, having side wall505, according to an exemplary embodiment of the present invention. Side wall505may be a left side wall or a right side wall of post office500. Rack member510may be configured to hold a plurality of p.o. boxes, each p.o. box having an open end opposite a lockable door, wherein said p.o. boxes are positioned such that said open ends face side wall505. Rack member510may be movably secured to at least one track member515via trolley520such that said rack may be positioned against side wall505, or pulled away from side wall505along track member515such that an authorized user may access the rear of rack member510in order to place deliveries, such as mail, to said plurality of p.o. boxes via the open ends facing side wall505. When positioned against side wall505, rack member510may be secured against side wall505with locking mechanism525. Locking mechanism525may have a horizontal member530movably secured against side wall505, and handle member535with which a user may slide horizontal member530horizontally against side wall505into a first position and a second position. In said first position, one or more hook members540mounted to horizontal member530may be configured to engage one or more corresponding loop members545mounted to the rear of rack member510. Thus, in said first position, rack member510is secured against side wall505and cannot be moved along track members515. In said second position, said horizontal member530is configured such that said one or more hook members540are configured to disengage from said one or more corresponding loop members545, thereby freeing rack member510to move along track members515. As previously discussed, certain embodiments of the present invention may further include a power system having power converter550and at least one back up battery555. Said power converter550may be configured to convert electricity from an electrical source to a suitable voltage and frequency for at least one of an internal light560, an air conditioner having vent565, or an internal electrical outlet, such as a standard 120 volt or 110 volt outlet. In some embodiments, said air conditioner may further include a thermostat mounted to an interior wall of post office500. FIG.6is a front view of a rack member605mounted inside a portable post office600, according to an exemplary embodiment of the present invention. Rack member605may include a frame member610by which rack member605is movably secured to track member615via a trolley620. In some embodiments of the present invention, track member615may be a Unistrut track, such as a 1⅝″, 12 gauge Unistrut track secured in a formed “HAT” wall angle mounted to the interior ceiling of post office600. In some embodiments, said trolley620may be a Unistrut Trolley #P2950 rated for at least 600 pounds. Some embodiments may movably secure rack member605to track member615via two trolley members620. Said track member615may be mounted or otherwise affixed to the ceiling of the interior of post office600. Some embodiments may further include ceiling material625, such as acoustical ceiling material or panels, such that track615appears to be mounted flush with the ceiling of post office600. Certain embodiments may further include weather stripping630at the top and/or bottom of rack member605, which weather stripping may be a brush seal or other such material configured to prevent the entry of debris to the area behind rack member605. Finally, some embodiments of the present invention may also include soffit635between the plurality of p.o. boxes615and weather stripping630to cover frame member610. Soffit member635may be configured to prevent access to frame member610, to prevent the introduction of debris to the area behind rack member605, and to achieve an aesthetically pleasing, “finished” look to rack member605. Soffit member635may be made of plywood, metal, plastic, vinyl, or other such suitable materials. FIG.7is a front, cross-section view of the interior of a portable post office700, according to an exemplary embodiment of the present invention. Portable post office700may include center aisle705with at least one rack member715on each of the left and right side walls710, wherein each rack member715is configured to hold a plurality of p.o. boxes, each p.o. box having a lockable door facing center aisle705and an open end opposite said door facing side wall710. Rack member715may further include frame member725by which rack member715is movably secured to track member720via trolley730. Track member720may be mounted or affixed to the interior ceiling of post office700perpendicular to side walls710. According to certain embodiments, each rack member715may be movably secured to track member720by at least two trolleys730. Rack member710may be configured to slide along said track member720so that it can be moved from a position against side wall710to a position in center aisle705, and back again. Some embodiments of the present invention may further include weather stripping735, which may be a brush stripping, and soffit740. FIG.8is a top view of the interior of a portable post office800, according to an exemplary embodiment of the present invention. Post office800may include side wall805, center aisle810, and rack member815. Rack member may be further configured to hold a plurality of p.o. boxes, each p.o. box having a lockable door facing center aisle810and an open end opposite said door facing side wall805. Rack member815may be movably secured to track member820via trolleys825. Track member820may be mounted to the interior ceiling of post office800perpendicular to side wall805. Thus, rack member815may be configured to travel along track member820from a first position against side wall805to a second position within center aisle810. When said rack member is in said first position, a user may access their individual assigned p.o. box via center aisle810, from which they may unlock said box to retrieve any contents therein. When mail is delivered, an authorized individual, such as a postal worker, may move rack member815along track member820to said second position within center aisle810such that said authorized individual may access the open ends of the plurality of p.o. boxes via the rear of rack member815in order to deliver mail, packages, or other materials to said p.o. boxes without having to unlock individual boxes from center aisle810. Said authorized individual may then return rack member815to said first position against side wall805. FIG.9ais a side view of the interior of a portable post office900having locking mechanism905, according to an exemplary embodiment of the present invention. Locking mechanism905is configured to secure one or more rack members925to a side wall of post office900. As discussed above, in certain embodiments of the present invention, rack member925may be movably secured to a track mounted to the ceiling of post office900such that rack member925may be positioned against a side wall of post office900or moved along said track to a center aisle of post office900to allow access to the rear of said rack member925for delivery of mail to p.o. boxes mounted within rack member925. Locking mechanism905may thus be configured to secure rack member925against said side wall to prevent unauthorized access to the unsecured openings of said p.o. boxes, which may be positioned to face the side wall of post office900. Said locking mechanism905may further include horizontal member910, which may be movably affixed to a side wall of post office900to allow for limited horizontal sliding movement against said side wall of post office900. Locking mechanism905may further include handle member915, by which a user may slide horizontal member910horizontally against said side wall. Finally, locking mechanism905may be further configured to be affixed to a side wall of post office900via lock920, thereby preventing the aforementioned horizontal movement of horizontal member910until lock920is removed. As will be demonstrated in subsequent figures, horizontal member910may include one or more hook members configured to engage with one or more corresponding loop members affixed to the rear of rack member925such that when said hook members are engaged with said loop members, rack member925is prevented from moving along said track and is instead affixed to said side wall of the post office900. FIG.9bis a close-up side view of a portion of a horizontal member910of locking mechanism905for portable post office900, according to an exemplary embodiment of the present invention. A portion of horizontal member910may extend behind rack member925along a side wall of post office900. Horizontal member910may be affixed to a side wall of post office900via slot930which is configured to engage with bolt935, which is welded, mounted, or otherwise affixed to a side wall of post office900. Thus, while horizontal member910is affixed to said side wall via bolt935, slot930, which may be shaped as an elongated oval, nevertheless allows horizontal member910to move horizontally along said side wall for a length equal to the horizontal length of slot930. For example, in certain embodiments of the present invention, horizontal member910may be a steel sliding angle having dimensions 2×2×⅛″, slot930may be a ½×2″ slot, and bolt935may be a ⅜×2″, grade 5 bolt. Some embodiments of the present invention may include multiple slots930along the length of horizontal member910configured to engage with corresponding bolts935affixed to the side wall of post office900. In such embodiments, slots930and corresponding bolts935may be positioned 3 feet on center. Finally, locking mechanism905may further include handle member915, which may allow a user to slide horizontal member910horizontally along said side wall of post office900for a distance equal to the length of slot935. FIG.10ais a front perspective view of the left portion of a portable post office1000, according to an exemplary embodiment of the present invention. Rack member1005, which may be configured to hold a plurality of p.o. boxes having lockable doors facing a center aisle of post office1000and open ends opposite said lockable doors facing side wall1020, may be movably secured to at least one track member1010via at least one trolley1015. Thus, rack member1005may be moved along track1010from a first position against side wall1020to a second position in said center aisle of said post office1000, such that an authorized user, such as a postal worker, may access the rear of rack member1005to deliver mail, packages, or other items to said plurality of p.o. boxes via said open ends. To prevent unauthorized access to the rear of rack member1005, rack member1005may be secured to side wall1020via locking mechanism1035in certain embodiments of the present invention. Accordingly, locking mechanism may include horizontal member1030movably affixed to side wall1020such that it may be moved horizontally along side wall1020between a first position and a second position via handle member1035. In said first position, at least one hook member1040affixed to horizontal member1030may be configured to engage with a corresponding loop member1045affixed to the rear of rack member1005. Thus, in said first position, the engagement of hook member1040with loop member1045prevents rack member1005from moving along track member1010, thereby securing rack member1005against side wall1020. When horizontal member1030is moved horizontally to said second position via handle member1035, hook member1040disengages from loop member1045, thereby releasing rack member1005from side wall1020and allowing rack member1005to move along track member1010. FIGS.10band10care a front view and a bottom view, respectively, of a portion of locking mechanism1025for portable post office1000, according to an exemplary embodiment of the present invention. Horizontal member1030is movably secured to side wall1020via slot1055, which may be configured to receive bolt1050, which may be welded, mounted, or otherwise affixed to side wall1020. Slot1055may be configured as an elongated, horizontal oval, thereby allowing limited movement of horizontal member1030along the length of slot1055, such that horizontal member1030may be moved into said first position and said second position. Horizontal member1030may be further affixed to bolt member1050through slot1055by a combination of threaded bolts1060and washers1065. Thus, in some embodiments of the present invention, threaded bolts1060may be positioned along bolt1050on either side of horizontal member1030, with washers1065acting as spacers between threaded bolts1060and horizontal member1030. Thus, horizontal member1030may be affixed to bolt1050while still allowing horizontal movement along the length of slot1055. In certain embodiments of the present invention, horizontal member1030may be a steel sliding angle having dimensions 2×2×⅛″, slot1055may be a ½×2″ slot, and bolt1050may be a ⅜×2″, grade 5 bolt. In said first position, loop member1045, mounted to the rear of rack member1005, is configured to receive hook member1040, mounted to horizontal member1030. Thus, in said first position, rack member is secured to side wall1020and cannot be moved along track member1010. When horizontal member1030of locking mechanism1025is moved into said second position, hook member1040is configured to disengage from loop member1045, thereby releasing rack member1005from side wall1020. Rack member1005is thus free to move along track1010. FIG.10dis a side view of a portion of locking mechanism1025for portable post office1000, according to an exemplary embodiment of the present invention. Handle member1035may be configured to allow a user to slide horizontal member1030horizontally against side wall1020for a length equal to the length of slot1055in order to move said horizontal member1030between said first position and said second position. Handle member1035may be mounted or affixed to side wall1020via pivot1070. Pivot1070may be welded, mounted, or otherwise affixed to side wall1020, and handle member1035may be affixed to pivot1070via pin1075. Thus, handle member1035may be configured to rotate about pivot1070. Handle member1035may be affixed to horizontal member1030via pivot1080. Pivot1080may be welded, mounted, or otherwise affixed to horizontal member1030, and handle member1035may be affixed to pivot1080via pin1085. Thus, in order to slide horizontal member1030between said first position and said second position, a user may rotate handle member1035back and fourth about pivot1070such that horizontal member1030moves along the length of slot1055. Locking mechanism1025may further include a first plate1090having hole1095, which may be welded, mounted, or otherwise affixed to handle member1035, and a second plate1100having hole1105, which may be welded, mounted, or otherwise affixed to side wall1020. Said first plate1090and said second plate1100may be configured such that when horizontal member1030is in said first position, wherein hook member1040is engaged with loop member1045, first plate1090contacts second plate1100such that holes1095and1105are concentrically aligned, thereby allowing the shackle of pad lock1110to pass through holes1095and1105. Thus, when said horizontal member1030is in said first position, locking mechanism1025can be secured in place via pad lock1110, thereby preventing rotation of handle member1035and thus securing rack member1005against side wall1020such that rack member1005cannot be moved along track member1010. Only when pad lock1110is removed from holes1095and1105can handle1035be rotated in a clockwise direction such that horizontal member1030can be moved into said second position, thereby disengaging hook member1040from loop member1045and thus freeing rack member1005for movement along track member1010. In certain embodiments of the present invention, pivots1070and1080may be ½″ pivots, and pins1075and1085may be ⅛″ Cotter pins. In further embodiments, handle member1035may be ¾″ diameter schedule40pipe, first plate1090and second plate1100may be ¼″ thick metal plates, and holes1095and1105may be ⅝″ diameter holes. In some embodiments, handle member1035may further include grip1115at the opposite end of handle member1035from pivot1070. Grip1115may be rubber, plastic, or other suitable material, and configured to allow a user to grasp handle member1035with a hand for rotation about pivot1070. While the embodiments of the present invention are described herein with reference to various implementations and exploitations, it will be understood that these embodiments are illustrative and that the scope of the invention(s) is not limited to them. In general, embodiments of a portable post office as described herein may be implemented using devices and materials consistent with any appropriate desired structure. Many variations, modifications, additions, and improvements are possible. For example, plural instances may be provided for components, operations, or structures described herein as a single instance. Boundaries between various components, operations, and functionality are depicted somewhat arbitrarily, and particular operations are illustrated within the context of specific illustrative configurations. For example, certain drawings contained herein illustrate particular arrangements of p.o. boxes mounted within rack members according to certain embodiments of the present invention. But these arrangements are for illustrative purposes only, and the present invention is in no way limited to said arrangements. P.O. Boxes are available in multiple sizes, and the present invention is intended to cover any arrangement and/or configuration of as may be required for a given deployment of a portable post office according to the present invention. In general, structures presented as separate components in the exemplary configurations may be implemented as a combined structure. Similarly, structures presented as a single component may be implemented as separate components or steps. These and other variations, modifications, additions, and improvements may fall within the scope of the inventive subject matter. While certain embodiments of the present invention reference the invention as a portable post office configured for use in an area affected by a natural disaster (and therefore in need of a temporary post office) it will be understood that the present invention is not limited to such deployments, but may also implemented anywhere where postal services are needed and cannot be provided by conventional means, such as in a rural area without a brick-and-mortar local post office to provide p.o. boxes for area residents. | 27,869 |
11859399 | Like reference symbols in the various drawings indicate like elements. DETAILED DESCRIPTION OF ILLUSTRATIVE IMPLEMENTATIONS To aid understanding, this document is organized as follows. First, to help introduce discussion of various implementations, an exemplary easy robust fence bracing system for quickly and securely brace a fence is introduced with reference toFIG.1. Second, that introduction leads to a description with reference toFIGS.2-4of some exemplary implementations of a fence bracing gearbox. Third, with reference toFIGS.5-7C, various implementations of an exemplary tension adjusting module are introduced. Fourth, with reference toFIGS.8-12, the discussion turns to exemplary implementations that illustrate various applications of an exemplary adaptive fence brace. Fifth, and with reference toFIGS.13A-15C, this document describes exemplary apparatus and methods useful for installing a secured fence using the easy robust fence bracing system. Finally, the document discusses further implementations, exemplary applications and aspects relating to an easy robust fence bracing system. FIG.1depicts an exemplary Easy Robust Fence Bracing System (ERFBS)100employed in an illustrative use-case scenario. For example, the ERFBS100may be a securely and safely constructed fence. In this example, the ERFBS100includes two vertical fence posts105, partially submerged at one end into a substrate110(e.g., a ground). For example, the fence posts105may be a T-post, a Y-post, or variants of a star post. In some implementations, the fence posts105may be made of steel. In this example, the fence post105includes, along a longitudinal axis of the fence post105, studs106. For example, the studs106may prevent, for example, a wire fence (not shown) from sliding up or down the fence post105. In some implementations, the wire fence may, by way of example and not limitation, include barbed wire. The wire fence may, for example, include high-tensile wire. In some examples, the wire fence may include net wire. Between the fence posts105, the ERFBS100includes a fence rail115coupled horizontally at each end to the fence post105. In some implementations, the fence rail115may be adjustable in length. For example, in use, the fence rail115may be adjusted in length to fit various distance between the fence posts105. In this example, the fence rail115includes an outer rail120, an inner rail125, and a coupling member130(e.g., a length adjustment bolt). In some implementations, at one or both sidewalls, each of the outer rail120and the inner rail125include multiple apertures spaced at intervals from an end of the rail. For example, by sliding the outer rail120relative to the inner rail125and aligning a pair of the apertures of the outer rail120and the inner rail125, the fence rail115may be adjusted into a desired length. For example, the coupling member130may be used to fix the fence rail at a desired length by bolting the overlapping ends in place by fastening through the aligned apertures between the inner rail125and the outer rail120. In some implementations, the fence rail115may, for example, include rectangular tubing (e.g., square tubing). A first fence rail may slide, for example, within a second fence rail. In some implementations, for example, the fence rail115may include an open shape (e.g., an “L-shape” such as angle iron). In the depicted example, the fence rail115is coupled (at opposing ends) to each of the fence posts105with an adaptive fence brace (AFB135). For example, the AFB135may provide flexibility in arranging the connection between the fence post105and the fence rail115. As shown in a close-up diagram depicted inFIG.1, the AFB135includes slots140configured to engage (e.g., mechanically couple) the studs106of the fence post105. In some implementations, the AFB135may include a clamp unit and a bracket to engage the fence post105such that the AFB135is securely fastened to the fence post105. Various implementations of the AFB135are further discussed with reference toFIGS.8-12. In the depicted example, the AFB135includes coupling features145to connect the fence post105with the fence rail115. For example, the coupling features145may receive a fastening bolt146to securely connect to the fence rail115. For example, therefore, the fence post105is securely connected to the fence rail115due to a secure engagement between the fence post105and the AFB135. In various implementations, the AFB135may provide more than one way for engaging the fence post105. Accordingly, the AFB135may, in some examples, advantageously provide flexibility in constructing the ERFBS100. The AFB135also includes coupling features150to diagonally couple to the adjacent fence post105via a tension adjusting rod155. In some implementations, by connecting to the adjacent fence post105, the ERFBS100may have additional reinforcement against rotational force (e.g., ‘torque’ or moment) against the ERFBS100. As shown in this example, the ERFBS100includes a Fence Bracing Gearbox (FBGB165). The FBGB165connects, in this example, two adjacent fence posts105diagonally by coupling the tension adjusting rod155and a coupling member160(e.g., a connecting link). For example, the FBGB165may be used to adjust tension between the fence posts105to advantageously improve reinforcement and stability. In some examples, a tension of the ERFBS100may be reduced after being used for some time due to, for example, weather condition and/or other outside disturbance. For example, the ERFBS100with reduced tension may have reduced strength. In some implementations, the FBGB165may be used to re-adjust the tension between the fence posts105to keep the fence strength at the desired level. In this example, the FBGB165further receives the coupling member160at a fixed length between the fence post105(in connection with the coupling member160) and the FBGB165. As shown in the zoom-in diagram B inFIG.1, the FBGB165receives the tension adjusting rod155though the FBGB165. As shown, a through length170may be allowed through the FBGB165. In some implementations, the FBGB165may adjust a tension between the two adjacent fence posts105by adjusting the through length170. For example, the tension between the fence posts105may be tightened by increasing the through length170. For example, the tension between the fence posts105may be loosened by decreasing the through length170. In some implementations, the FBGB165may further include a locking unit. For example, the locking unit may be a nut threading along the tension adjusting rod155. In some implementations, the locking unit may be tightened against the FBGB165to secure the through length170of the tension adjusting rod155. The ERFBS100includes a tension adjusting brace175. As shown, the tension adjusting brace175may provide a tension adjusting function without using a gearbox. FIG.2AandFIG.2Bdepict an exemplary FBGB165coupled to an exemplary tension adjusting rod155and an exemplary coupling member160, with hook ends (FIG.2A) and engagement ends (FIG.2B). For example, the tension adjusting rod155may be a threaded shaft. For example, the tension adjusting rod155may be connecting on one end to the fence post105. For example, the coupling member160may be connecting diagonally to another fence post. The coupling member160is received at a gearbox housing205. The FBGB165further includes a handle210for operating an internal gear system (not shown). For example, the internal gear system may be used to regulate a relative position of the tension adjusting rod155to the FBGB165. The tension adjusting rod155, in this example, is a fully threaded rod. In other implementations, the tension adjusting rod155may be a partially threaded rod that is threaded at an end portion. In some examples, the tension adjusting rod155may be partially threaded so that it is easy to grip at either end of the tension adjusting rod155. A rod (e.g.,155,160) may be provided with a terminal end (e.g., at a distal end relative to the FBGB165). In the depicted example inFIG.2A, a distal end of the tension adjusting rod155and the coupling member160are each provided with a hook end215. For example, the hook end215may be used to engage a post and/or an AFB135. Accordingly, for example, a user may apply the FBGB as a reusable tensioning tool to apply tension to a fence (e.g., a brace, wire). For example, the user may use the FBGB165to tension the fence, and then apply a diagonal bracing rod, a tension adjusting brace175, wire, and/or cable. In the depicted example inFIG.2B, a distal end of the tension adjusting rod155and the coupling member160are each provided with an engagement end220. The engagement end220, as depicted, may be configured to be coupled (e.g., by a pin, screw, and/or bolt) to an AFB135, for example. For example, the FBGB165may be installed (e.g., permanently, semi-permanently) as an adjustable tension fence bracing module (e.g., diagonal fence brace). The terminal ends (e.g.,215,220) may be releasably coupled to the respective rod(s). For example, a terminal end may be threaded to receive the distal end of the corresponding rod. In some implementations, a terminal end may be fixedly coupled (e.g., welded) to the rod. In some implementations, a terminal end may be pinned to a rod. Some implementations may, by way of example and not limitation, be rotatably coupled (e.g., by a swivel joint such as a swaged swivel joint) to the rod. Implementations with a swivel joint may, for example, advantageously enable repositioning of the FBGB165to a desired orientation for operation. In some examples, various materials may be used to make one or more components. For example, the tension adjusting rod155may be made in aluminum for better durability and less weight. In some examples, the tension adjusting rod155may be made in brass rods for higher corrosion resistivity. Other metal materials, such as steel, titanium, bronze, and/or copper may be used, in some implementations. In some implementations, polymers and/or fiber reinforced polymers (e.g., carbon fiber, fiberglass), for example, may be used. FIG.3is a cross section-view of the FBGB165as described with reference toFIGS.2A-2B. In this example, the FBGB165includes a ring gear305operably coupled to a pinion gear310. For example, a rotation of the pinion gear310may induce a corresponding rotation at the ring gear305. In this example, the pinion gear310operably couple to the handle210. For example, a rotational motion at the handle210may induce rotation at the pinion gear310, which, in turn, may induce rotations at the ring gear305. As shown, the FBGB165includes a threaded lumen315for receiving the tension adjusting rod155. For example, the tension adjusting rod155may be rotatably inserted into the threaded lumen315. In some implementations, at least part of the threaded lumen315may be driven by the ring gear305. For example, the ring gear305may rotate a part of the threaded lumen315to regulate a relative position of the tension adjusting rod155to the FBGB165. The FBGB165includes a bracing chamber320configured to releasably couple to the coupling member160. In some implementations, the bracing chamber320may be threaded to securely receive the coupling member160. In some implementations, the bracing chamber320may include friction inducing material to secure the coupling member160in place. As shown, the bracing chamber320may receive the coupling member160at a substantially parallel axis to the threaded lumen315. The bracing chamber320includes a soft stop unit325. In some implementations, during insertion of the coupling member160into the bracing chamber320, the soft stop unit325may advantageously provide tension relief to avoid damage to the bracing chamber due to excessive tension. In some implementations, the soft stop unit325may be a rubber stop. In some implementations, the soft stop unit325may be a coil spring. FIG.4shows an exemplary gear arrangement of the FBGB165as described with reference toFIGS.2A-2B. In this figure, the housing205is removed for better view of the internal gear system. The ring gear305includes an extended bore405to receive the tension adjusting rod155. For example, the extended bore405may be configured to threadedly engage the tension adjusting rod155. In operation, the handle210may be operated to turn the pinion gear310. The pinion gear310, having an axis of rotation substantially perpendicular to the ring gear305, may induce a rotation at the ring gear305such that the extended bore405may concentrically engage the tension adjusting rod155. For example, the relative position of the tension adjusting rod155to the FBGB165may be altered. In some examples, the tension between the fence posts connected by the FBGB165may be advantageously selectively regulated. In various implementations, during a setup of the ERFBS100, the FBGB165may selectively operate in a sliding mode in which the tension adjusting rod155is permitted to slide in the threaded lumen315along a first longitudinal axis. The FBGB165may operate, in some implementations, in a threading mode in which the ring gear305threadedly couples tension adjusting rod155to the FBGB165. In some examples, the ring gear305may be rotated operably by the handle210to selectively adjust the tension at the FBGB165. After a desired tension is reached, in some implementations, the FBGB165may operate in a locking mode in which the locking unit clamps the tension adjusting rod in a static position relative to the FBGB165. In some implementations, the FBGB165may not include a sliding mode. FIG.5depicts a perspective view of an exemplary tension adjusting brace175. In various examples, the tension adjusting brace175may be used in place of the FBGB165inFIG.1. As shown in, the tension adjusting brace175includes a channel505for receiving the tension adjusting rod155, and a chamber510for receiving the coupling member160. In this example, the tension adjusting brace175further includes a turning member515(e.g., a knob, as depicted). In some implementations, the turning member515may, for example, be configured as a bolt. For example, the turning knob may be operable by a tool (e.g., a wrench). The turning knob may, for example, omit a handgrip in some implementations. FIG.6depicts a cross-section diagram of the tension adjusting brace175as described inFIG.5. As shown, the turning member515has a threaded shaft operably engaging a clamping block605. For example, rotations of the turning member515may induce the clamping block605to move in an axis perpendicular to a longitudinal axis along the channel505. In some examples, when the channel505receives the tension adjusting rod155, the clamping block605may engage and prevent the tension adjusting rod155from sliding. In various implementations, the clamping block605may be threaded to advantageously exert a firm grip on the threaded tension adjusting rod155. In the depicted example, the clamping block605may, be at least partially elastomeric. For example, the clamping block605may include at least one terminal pad610and terminal pad615(e.g., natural rubber, vulcanized rubber, polyurethane). In some implementations, the terminal pad may, by way of example and not limitation, be formed from Shore D 60-80 durometer material. Such a relatively rigid rubber may advantageously resist rotation and/or axial displacement of the tension adjusting rod155when the clamping block605is operated into a locked mode. In some implementations, the terminal pad610may, for example, be a metal (e.g., deformable under a predetermined clamping pressure). The terminal pad610may, for example, be aluminum (e.g., 6010 aluminum), brass, and/or copper. In some implementations, the terminal pad610may, for example, be threaded. The terminal pad615may, for example, regulate a maximum clamping force. A space tolerance between the clamping block605and the corresponding cavity in the brace175may, for example, permit the clamping block605to move axially (e.g., parallel to the channel505) during engagement of the at least one terminal pad610with a (threaded) rod (e.g., to permit threads of the terminal pad610to engage threads of the rod). In some implementations, in a tension adjusting operation, a desired tension may be achieved by sliding the tension adjusting rod155to a desired length relative to the tension adjusting brace175. In some examples, the turning members515can be turned to increase friction between the clamping block605and the tension adjusting rod155. For example, the tension adjusting rod155may be prevented from sliding when the friction is above a (predetermined) threshold. Accordingly, for example, the tension adjusting brace175may provide an alternative option for regulating the tension at the tension adjusting rod. In some implementations, the tension adjusting brace175may advantageously provide a more affordable alternative for diagonally bracing the fence posts105. In some implementations, terminal ends of the rod(s) may be provided with swivel joint(s), such as discussed with respect toFIGS.2A-2B. In such implementations, for example, the terminal ends of the rods may be engaged with opposite ends to be braced (e.g., a first post and a second post). The turning member515may be operated such that the clamping block605is in a sliding mode (e.g., allowing a rod to slide axially through the channel505). For example, a coefficient of friction and/or normal force is below a corresponding predetermined threading threshold Tt. Once the rod is in a desired position, the turning member515may be operated such that the clamping block605is in a threading mode (e.g., engaging the rod such that a coefficient of friction and/or normal force is above the corresponding Tt and below a corresponding predetermined clamping threshold Tc). The rod and/or the brace175may be rotated relative to one another such that the rod is axially translated, relative to the brace175, along a longitudinal axis of the channel505. Accordingly, the rod may advantageously be threaded to apply, for example, a desired tension to the rod(s). Once a desired tension is achieved, the turning member515may be operated such that the clamping block605is in a clamping mode. For example, a coefficient of friction and/or a normal force may be above the corresponding Tc. For example, Tc>Tt. Accordingly, a user may advantageously quickly position a rod in a sliding mode, generate a desired tension in a threading mode, and then clamp the rod in place. FIG.7Ashows an exemplary tension adjusting brace700having two receiving channels705,710. In some implementations, the ERFBS100may include two tension adjusting rods155diagonally coupled to the tension adjusting brace700. In some examples, the tension adjusting brace700may adjust tension of each of the tension adjusting rods155received by adjusting a relative position between the tension adjusting brace700and the corresponding tension adjusting rods155. The tension adjusting brace700further includes two control members715,720. In some implementations, the control members715,720may be a hexagonal socket. For example, the control members715,720may be controlled by inserting and rotating a hexagonal wrench (e.g., an Allen wrench such as a Z-Allen wrench). FIG.7Bshows a cross-section view of the exemplary tension adjusting brace700as described inFIG.7A.FIG.7Cshows an exploded view of the exemplary tension adjusting brace700as described inFIG.7A. In this example, the tension adjusting brace700includes, for each of the channels705,710, clamping blocks725. Each of the clamping blocks725may be used to hold a received tension adjusting rod. Each of the clamping blocks725may be in pressing contact, in this example, with the corresponding control members715,720(depicted as bolts with sockets). In various examples, the spring coil730may be received in a tension relief chamber755such that excess tension is avoided to prevent damage to the tension adjusting rods or the tension adjusting brace700. The spring coil730may, for example, urge the clamping blocks725away from the channels705such that a vertical position of the clamping blocks725is determined by a position of the control members715,720in a block top740(e.g., through a threaded hole, as depicted). As depicted, the block top740is coupled (e.g., releasably) to the body of the brace700by fasteners744(e.g., press-fit, threaded) engaging cavities745(e.g., threaded, sized to pressingly receive the fasteners). A cavity750is configured to (slidingly) receive the clamping blocks725into the body of the brace700. In some implementations, the clamping blocks725may, for example, be configured as disclosed at least with reference to the clamping block605. In some implementations, for example, the clamping blocks725may include corresponding rubber pads. In some implementations, such as depicted, the clamping blocks725may include a threaded block735. The threaded block735, as depicted, includes a threaded end configured to selectively engage a threaded rod operated through a corresponding lumen (e.g., channels705,710) in response to operation of the control members715,720. In some implementations, in operation, when the control member715is rotated and driven towards the channels705, the spring coil730may be pressed towards the clamping block725. For example, when a tension adjusting rod is received at the channel705and the control member715is rotated towards the channel, the tension adjusting rod may be secured at a desire position at the tension adjusting brace700. FIG.8depicts a perspective view of an exemplary adaptive fence brace (AFB)135bracing a fence post105. As shown, the AFB135includes a butterfly clamp805and a C-bracket810. In this example, the butterfly clamp805is installed on the blade side of the fence post105. The C-bracket810is installed on the opposite side, the stud side of the fence post105. As shown, a corresponding side wall815of the C-bracket810extends from each side in the same direction as a blade820of the fence post105in this configuration. The body of the fence post105is, as shown in this example, sandwiched between the butterfly clamp805and the C-bracket810. In this example, the butterfly clamp805and the C-bracket810are fastened to each other and consequently to the fence post105using bolts825a,825b(e.g.,825bmay have a larger diameter than825a, such as corresponding to a diameter of the corresponding aperture). As shown, the fence post105includes studs830that protrude through the slots140when the AFB135is secure at the fence post105. FIG.9depicts a perspective view of an exemplary butterfly clamp805. In this example, the butterfly clamp805includes a rib receiving channel905. For example, the rib receiving channel905may receive a ridge portion of a T-post along a longitudinal axis. From the rib receiving channel905, the butterfly clamp805includes two side walls815. In this example, the side walls815include two pairs of horizontally aligned first apertures915. In some implementations, the first apertures915may be registered, in use, with a bracket to securely couple to a T-post. The side walls815further includes one pair of horizontally aligned second apertures920, in this example. In some implementations, the second aperture920may be larger than the first aperture915. For example, the second aperture920may be used to couple with the tension adjusting rod155and/or the coupling member160. In this example, the butterfly clamp805further includes an adaptive facing925between the rib receiving channel905and each of the side walls815. In some implementations, the adaptive facing may provide room for adaptively coupling to fence posts of different sizes and thickness. FIG.10depicts a perspective view of an exemplary C-bracket810. The C-bracket810includes a back wall1105. The back wall1105may, as shown in this example, engage a stud side of the fence post105. In this example, the C-bracket810includes two slots140for receiving the studs830of the fence post105. The C-bracket810also includes, in this example, first apertures1005and second apertures1010for registering with the butterfly clamp805. For example, studs of a T-post may protrude through the slots140. The back wall1105includes two pair of horizontally aligned first apertures1005. In some implementations, the first apertures1005may be registered to the first apertures915of the butterfly clamp805. The back wall1105further includes one pair of horizontally aligned second apertures1010, in this example. In some implementations, the second aperture1010may be larger than the first aperture1005. For example, the second aperture1010, together with the second aperture920, may be used to securely couple with the tension adjusting rod155or the coupling member160. In the depicted example, the C-bracket810includes side walls815extending perpendicularly from the upper ⅔ of the back wall1105. In some implementations, each of the side walls815may include horizontally disposed (two) sets of transversely opposed apertures1115for fastening devices. In various implementations, transversely opposed apertures1115may be used to couple the fence posts105to the fence rails115. In some implementations, the butterfly clamp805may also be coupled to a bracket that is a flat plate having features as described as the back wall1105. In some implementations, a combination of the apertures920, the corresponding apertures1010, and bolts825a,825bwith accompanying nuts1205a,1205bmay be dual purpose. For example, the combination may be used to fasten the tension adjusting rod155and the coupling member160to the AFB135in addition to reinforcing the corresponding brackets to the fence posts105. FIG.11shows a top view of an exemplary AFB135. As shown in this example, when the butterfly clamp805and the C-bracket are combined, the AFB135includes a pinch gap1305created by the adaptive facing925of the butterfly clamp805. Accordingly, the AFB135may advantageously adapt to fence post105of various size and thickness. FIG.12shows a second exemplary arrangement of an exemplary AFB135combining the butterfly clamp805ofFIG.9, the C-bracket810ofFIG.11, and the fence post105. As shown, the butterfly clamp805, the C-bracket810, and the fence post105are fastened in a similar manner as described inFIG.8. As shown, the C-bracket810is fastened to the butterfly clamp805with the bolts825a,825band nuts1205a,1205b. In this example, the side walls815extends in the opposite direction as the blade820. FIG.13A,FIG.13B, andFIG.13Cillustrate top plane views of an exemplary AFB135arrangements having one end of a fence rail115installed at various locations of the AFB135. Referring toFIG.13A, the fence rail115at one end is installed in between the side walls815of the C-bracket810. As shown, a fastening bolt1505traverses through a pair of apertures1115a,1115bon the side walls815, and through apertures of the fence rail115. For example, the fastening bolt1505is secured with an internally threaded nut1510threaded over the externally threaded segment of the fastening bolt1505. Referring toFIG.13B, the fence rail115is installed on an outside of one of the side walls815of the C-bracket810. In this example, the side walls815(e.g., sidearms) are on a stud side of the fence post105. As shown, the fastening bolt1505traverses an aperture on the fence rail115and the apertures1115on the side walls815. For example, the fastening bolt1505is secured with an internally threaded nut1510threaded over an externally threaded segment of the fastening bolt1505. Referring toFIG.13C, the fence rail115is installed in between the side walls815. As shown in this example, the side walls815are on the blade side of the fence post105. In this case, the fastening bolt1505may, for example, traverses an outer set of the apertures1115of the side walls815. FIG.14A,FIG.14B,FIG.14C, andFIG.14Dshow top plane views of exemplary AFBs135that couple two fence rails115. Referring toFIG.14A, the AFB135is coupled to another C-bracket810b, creating an extended AFB1600having a combination of C-brackets810a,810b. In some examples, either side of the AFB1600may have side walls815available for fastening the fence rails115. As shown in this example, a first fence rail115ais fastened at the C-bracket810a, and a second fence rail115bis fastened at the C-bracket810b. Referring toFIG.14B, the fence rails115a,115bare installed on the outside of the side walls815of the AFB135. A fastening bolt1605, in this example, traverses the fence rail115a, the inner set of the apertures1115, and the fence rail115b. In this example, the fastening bolt1605is secured with a nut1610. A similar installation of fence rails on the AFB135is shown inFIG.14C. The fence rails115a,115b, as shown in the example shown inFIG.14C, are installed on the outside of the side walls815of the AFB135. A fastening bolt1605, in this example, traverses the fence rail115a, the outer set of the apertures1115, and the fence rail115b. In this example, the fastening bolt1605is secured with a nut1610. To brace corners and T-junctions of fences, the fence rails115, in some implementations, may be installed perpendicular to each other. As shown inFIG.14D, the AFB135is installed on a corner fence post. The fence rail115a, for example, may be fastened on the outside of the side walls815. The fence rail115bmay be fastened in between the sidearms, for example. A fastening bolt1605may, in some implementations, traverse an end of the fence rail115a, the aperture1115a, a side of the fence rail115b, and the aperture1115b. The fastening bolt1605may be secured with the nut1610, for example. FIG.15A,FIG.15B, andFIG.15Cshows exemplary applications of ERFBS100with wood posts, T-posts, and a combination thereof. For example,FIG.15Adepicts a corner fence brace1701constructed using fence post105(t-posts, as depicted). In various implementations, adjacent fence posts105may be diagonally braced by either one or two tension adjusting rods. As shown inFIGS.15B-15C, a brace may be constructed at least partially using a wood post1705. For example, corner fence brace1702depicts a corner wood post1705coupled to two t-posts (fence post105). Corner fence brace1703depicts three wood posts1705. As depicted, a tension adjusting rod may be coupled to the wood post1705(e.g., instead of using the AFB135), via a coupling feature of the fence rail115. For example, a coupling member1710may be embedded in the wood post1705. The coupling member1710may, for example, be a bolt fastened through a hole drilled in the wood post1705. In some embodiments, an end of the tension adjusting rod (e.g., coupled to the brace175and/or the brace700) may be directly coupled to the coupling member1710(e.g., instead of being coupled to the fence rail115). In some examples (not shown), an AFB135may be coupled to the wood post1705(e.g., through first apertures1005and/or second apertures1010). The fence rail115and/or a tension module (e.g., brace175, brace700) may be coupled to the wood post1705via the AFB135. FIG.16AandFIG.16Bdepict exemplary bracing rails. As depicted inFIG.16A, the fence rail115is assembled from an inner rail125and an outer rail120. In the depicted example, the inner rail125and the outer rail120each have a substantially rectangular cross-section (e.g., a square cross-section, as depicted). The inner rail125is configured to be slidingly received within the outer rail120. The inner rail125is provided with a first set of apertures1820distributed along the longitudinal axis of the inner rail125. The outer rail120is provided with a second set of apertures1825distributed along the longitudinal axis of the outer rail120. When the longitudinal axes of the inner rail125and the outer rail120are aligned and the inner rail125and the outer rail120are slid together to a desired length such that at least one of the first set of apertures1820is aligned with a at least one of the second set of apertures1825, a coupling member130(e.g., a bolt and nut, a pin) may be coupled through the corresponding apertures to fix the fence rail115at a desired length. In the depicted example, the inner rail125and the outer rail120each are provided with an aperture1835aat a distal end. For example, the aperture1835amay be used to fasten the distal end of the rail to a post (e.g., directly, by a bolt, to an AFB135). An aperture1815may, for example, be configured to provide access into an interior of the rail to reach an inner side of the distal end (e.g., to reach the inside of the aperture1835a). The aperture1815may, for example, advantageously provide access to fasten a bolt, nut, and/or other coupling member. In the depicted example, the inner rail125and the outer rail120are each provided with at least one aperture1835bjust proximal of the distal end. For example, the at least one aperture1835bmay be used to couple the fence rail115to a host (e.g., a post, an AFB135, an anchor in a wood post). As depicted, the inner rail125and the outer rail120are each provided with a coupling member1840(e.g., a tab with a hole, as depicted) extending substantially orthogonally from the longitudinal axis. The coupling member1840may, for example, couplingly receive (e.g., by a bolt, a pin, a rivet) an end of a diagonal bracing rod (e.g., engagement end220of the FBGB165, rod155and/or coupling member160of the brace175and/or brace700. As depicted inFIG.16B, the fence rail115is assembled from a first rail1850and a second rail1855. In the depicted example, the first rail1850is provided with a first set of apertures1860. The second rail1855is provided with a second set of apertures1865. In the depicted example, the apertures1865each extend (e.g., as slots) in a first direction substantially parallel to a longitudinal axis of the fence rail115. The apertures1860each extend (e.g., as slots) in a second direction substantially orthogonal to the longitudinal axis of the fence rail115. When the first rail1850and the second rail1855are brought into alignment such that their corresponding longitudinal axes are substantially aligned, the first rail1850and the second rail1855may be coupled together by at least one coupling member130being coupled through corresponding apertures of the first set of apertures1860and the second set of apertures1865. As depicted, by the apertures1860and the apertures1865extending in different direction (e.g., substantially orthogonal to each other, as depicted), a user may easily align the apertures to insert the at least one coupling member130through them. The slots may, for example, advantageously enable the apertures to be aligned regardless of offset in the holes due to a thickness of the first rail1850and the second rail1855. For example, the slots may allow the first rail1850and the second rail1855to be interchangeably used as an inner or outer rail (e.g., nested inside each other with either one being able to be nested inside the other and/or sitting over the other). Although various implementations have been described with reference to the figures, other implementations are possible. In some implementations, the FBGB165may include various gearing ratio. For example, the ring gear305and the pinion gear310may have a 1:1-3:1 ratio. In some implementations, a worm gear may be used at the FBGB165. The worm gear may, for example, be a reducing gear. In some implementations, the FBGB165may include a self-braking system. For example, when the tension at the tension adjusting rod155is above a threshold, the FBGB165may automatically stop length adjustment of the tension adjusting rod. For example, the self-braking system may avoid over tension of at the FBGB and protect the fence from damage. In some implementations, a reducing worm gear (e.g., driving the ring gear305, such as in place of the pinion gear310) may be configured as the self-braking (e.g., self-locking) system. For example, the worm gear may prevent rotation of the ring gear305in response to tension applied to the threaded rod. Some such implementations may, for example, not have stop blocks. In some implementations, torque transmission may be provided by the ring gear305and the pinion gear310, such as depicted in the corresponding figures. In some examples, the ring gear305and/or a drive gear (e.g., the pinion gear310) may be configured as a bevel gear. A gear may, for example, be implemented as a spur gear. Some implementations (e.g., of the FBGB165) may include a stop block(s). For example, the stop block may be configured as a self-braking mechanism. In some implementations, the stop block may be configured as a manually-activated braking mechanism. The stop block may, for example, clamp against a rotating member (e.g., a gear, the threaded rod) to prevent rotation of the threaded rod in response to tension. Some implementations may, for example, omit the stop block(s). In some implementations, a clamping block (e.g.,605,725) may be configured as a floating block. For example, the floating block may be positioned within a cavity in the corresponding body (e.g.,175,700) that is larger in at least one dimension. The floating block may, therefore, have room to ‘float’ along at least one axis such that the block may align with a threaded rod (e.g., to matingly align threads when being operated into a threading or clamping mode from a sliding mode). Terminal pads (e.g.,615) may, for example, be provided within the cavity to provide a (predetermined) minimum friction, prevent ‘rattling’ and/or reduce ‘slop’ (e.g., when the block is clamped such as by515,715, and/or720). In some implementations, the pinion gear310may be driven by a hexagonal socket. For example, the pinion gear310may be operated by inserting an Allen wrench into the hexagonal socket. Although an exemplary system has been described with reference toFIG.1, other implementations may be deployed in other industrial, scientific, medical, commercial, and/or residential applications. In an illustrative aspect, a post brace bracket may include a butterfly clamp. The butterfly clamp may include a rib-receiving channel configured to receive a first longitudinal rib of a fence post. The fence post may extend along a longitudinal axis. The butterfly clamp may include tabs extending from corresponding proximal edges of the rib-receiving channel and configured to register with a second longitudinal rib of the fence post. The first longitudinal rib and the second longitudinal rib may intersect in a plane orthogonal to the longitudinal axis. The post brace bracket may include a receiver bracket. The receiver bracket may include a first wall including a fastening aperture configured to receive at least one stud extending from a face of the second longitudinal rib. The receiver bracket may include two side walls extending from opposite edges of the first wall and each comprising a coupling aperture configured to releasably couple to a lateral rail. When the butterfly clamp and the receiver bracket are coupled together at either side of the first wall, the fastening aperture may engage the at least one stud to resist translation parallel to the longitudinal axis and the rib-receiving channel may engage the first longitudinal rib to resist rotation about the longitudinal axis. When the butterfly clamp and the receiver bracket are coupled together, the two side walls may be configured to releasably couple to multiple lateral rails, such that each of the multiple lateral rails extends substantially orthogonally away from the fence post. The proximal edges of the rib-receiving channel may include an offset bridge connecting a horizontal plane of the tabs and a plane of the proximal edges such that, when the butterfly clamp and the receiver bracket are coupled together to brace a fence post, the offset bridge and the first wall of the receiver bracket create an adaptive space configured to fit multiple shapes of the fence post. The post brace bracket may include a second receiver bracket coupled to the receiver bracket. The two side walls may each extend from substantially two-thirds of the corresponding proximal edges of the first wall. The two side walls may include more than one pair of coaxially aligned coupling apertures to releasably couple to a lateral rail. In an illustrative aspect, a tensioning module may include a channel defining a lumen having an aperture at a distal end and configured to slidingly receive a threaded rod through the channel such that the threaded rod extends along a first longitudinal axis. The tensioning module may include a coupling member at a proximal end configured to couple to a connecting link extending along a second longitudinal axis substantially parallel to the first longitudinal axis. The tensioning module may include a ring gear concentrically and at least partially threadedly coupled to the threaded rod such that, when the ring gear is rotated, the threaded rod is induced to move along the first longitudinal axis. The tension module may include a second gear operably coupled to the ring gear and having an axis of rotation perpendicular to that of the ring gear. The second gear may be configured such that, when the second gear is rotated in a first rotational direction, the second gear induces a rotational motion of the ring gear about the threaded rod such that a position of the threaded rod relative to the tensioning module is altered. The second gear may include a pinion gear. The second gear may include a worm gear. The tensioning module may include a lever arm configured to induce rotation of the second gear when the handle is operated by a user. The lever arm and include a handle releasably coupled to the second gear. The ring gear may be mounted to a housing by at least one rolling bearing. The coupling member may include a threaded channel configured to receive the connecting link such that a position of the connecting link relative to the channel is adjustable. In an illustrative aspect, a tensioning module may include a body including a channel defining a lumen having an aperture at a distal end of the body and extending substantially through the body. The channel may be configured to slidingly receive a tension adjusting link through the channel such that the tension adjusting link extends along a first longitudinal axis. Tensioning module may include a coupling feature at a proximal end of the body. The coupling feature may be configured to couple to a connecting link extending along a second longitudinal axis substantially parallel to the first longitudinal axis. Tensioning module may include a tension regulation module configured to selectively engage the tension adjusting link with the tensioning module. The tension regulation module may be selectively operable between: a sliding mode in which the channel is configured to permit the tension adjusting link to slide in the lumen along the first longitudinal axis, and a tension adjusting mode in which the tension regulation module performs tension adjusting operations to the tension adjusting link such that a position of the tension adjusting link relative to the tensioning module is altered such that a tension between a proximal end of the connecting link and a distal end of the tension adjusting link is adjusted. The tension adjusting link may include a threaded rod. The tension adjusting mode may be a threading mode in which the tension regulation module threadedly engages the threaded rod in the channel. In the tension adjusting mode, the tension adjusting operation may include threadedly couple the threaded rod and the tension regulation module. The tension regulation module may include a clamping block configured to selectively engage the tension adjusting link. The tension regulation module may include a tension application unit operably coupled to the clamping block such that, when a force perpendicular to the first longitudinal axis is applied, the clamping block engages the tension adjusting link to regulate the position of the tension adjusting link relative to the tensioning module. The clamping block may include a threaded surface configured to threadedly engage the tension adjusting link. The clamping block and include an elastomeric end module. The elastomeric end module may be configured with a durometer rating of at least Shore D 60. The tensioning module may include a locking module. The tensioning module may be further selectively operable in a locking mode in which the locking module clamps the tension adjusting link in a static position relative to the tensioning module. The coupling feature may include a connecting link receiving end module configured to relieve excess tension to the tensioning module. The coupling feature may include a coil spring. The tension regulation module may be further configured to selectively engage the connecting link such that a tension of the connecting link and a tension of the tension adjusting link are independently adjustable. The coupling feature include a threaded channel to receive the connecting link such that a position of the connecting link relative to the channel is adjustable. The tension regulation module may further include a miter gear releasably coupled to the threaded rod. An illustrative aspect, an adaptable fence bracing rail may include a first rail extending along a first longitudinal axis. The first rail may include a first aperture at a distal end. The first rail may include a first plurality of apertures in a wall of the first rail distributed along at least a portion of the first rail in a first line substantially parallel to the first longitudinal axis. The adaptable fence bracing rail may include a second rail extending along a second longitudinal axis. The second rail may include a second aperture at a distal end. The second row may include a second plurality of apertures in a wall of the second rail distributed along at least a portion of the second rail in a second line substantially parallel to the second longitudinal axis. The first rail and the second rail may be configured such that, when the first rail and the second rail are brought into register such that the first longitudinal axis and the second longitudinal axis are substantially aligned, and at least one coupling member passes through at least one of the first plurality of apertures and at least one of the second plurality of apertures to couple the first rail to the second rail, then the first rail and the second rail are coupled into a field-adjustable bracing rail wherein the distal end of the first rail and the distal end of the second rail form opposite ends of the field-adjustable bracing rail. The field-adjustable bracing rail may be configured to be coupled to a first post by the first aperture and a second post by the second aperture such that the field-adjustable bracing rail resists compressive force induced by motion of the first post and the second post towards each other. At least one of the first aperture and the second aperture may be configured to couple the corresponding end of the field-adjustable bracing rail to a bracket coupled to a post in a predetermined orientation to the post. The first plurality of apertures may include slots extending substantially parallel to the first longitudinal axis. The second plurality of apertures may include slots extending substantially orthogonal to the second longitudinal axis. At least one of the first rail and the second rail may be substantially defined by an L-shaped cross-section. At least one of the first rail and the second rail may be substantially defined by a closed cross-section. The closed cross-section may be substantially rectangular. At least one of the first rail and the second rail may be configured to slidingly assemble into the other of the first rail and the second rail. The adaptable fence bracing rail may include a coupling member extending substantially orthogonally from at least one of the first longitudinal axis and the second longitudinal axis. The coupling member may be configured to releasably couple to a diagonal tension member. A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made. For example, advantageous results may be achieved if the steps of the disclosed techniques were performed in a different sequence, or if components of the disclosed systems were combined in a different manner, or if the components were supplemented with other components. Accordingly, other implementations are contemplated within the scope of the following claims. | 48,655 |
11859400 | Like reference symbols in the various drawings indicate like elements. DETAILED DESCRIPTION OF ILLUSTRATIVE IMPLEMENTATIONS To aid understanding, this document is organized as follows. First, to help introduce discussion of various implementations, an exemplary easy robust fence bracing system for quickly and securely brace a fence is introduced with reference toFIG.1. Second, that introduction leads to a description with reference toFIGS.2-4of some exemplary implementations of a fence bracing gearbox. Third, with reference toFIGS.5-7C, various implementations of an exemplary tension adjusting module are introduced. Fourth, with reference toFIGS.8-12, the discussion turns to exemplary implementations that illustrate various applications of an exemplary adaptive fence brace. Fifth, and with reference toFIGS.13A-15C, this document describes exemplary apparatus and methods useful for installing a secured fence using the easy robust fence bracing system. Finally, the document discusses further implementations, exemplary applications and aspects relating to an easy robust fence bracing system. FIG.1depicts an exemplary Easy Robust Fence Bracing System (ERFBS)100employed in an illustrative use-case scenario. For example, the ERFBS100may be a securely and safely constructed fence. In this example, the ERFBS100includes two vertical fence posts105, partially submerged at one end into a substrate110(e.g., a ground). For example, the fence posts105may be a T-post, a Y-post, or variants of a star post. In some implementations, the fence posts105may be made of steel. In this example, the fence post105includes, along a longitudinal axis of the fence post105, studs106. For example, the studs106may prevent, for example, a wire fence (not shown) from sliding up or down the fence post105. In some implementations, the wire fence may, by way of example and not limitation, include barbed wire. The wire fence may, for example, include high-tensile wire. In some examples, the wire fence may include net wire. Between the fence posts105, the ERFBS100includes a fence rail115coupled horizontally at each end to the fence post105. In some implementations, the fence rail115may be adjustable in length. For example, in use, the fence rail115may be adjusted in length to fit various distance between the fence posts105. In this example, the fence rail115includes an outer rail120, an inner rail125, and a coupling member130(e.g., a length adjustment bolt). In some implementations, at one or both sidewalls, each of the outer rail120and the inner rail125include multiple apertures spaced at intervals from an end of the rail. For example, by sliding the outer rail120relative to the inner rail125and aligning a pair of the apertures of the outer rail120and the inner rail125, the fence rail115may be adjusted into a desired length. For example, the coupling member130may be used to fix the fence rail at a desired length by bolting the overlapping ends in place by fastening through the aligned apertures between the inner rail125and the outer rail120. In some implementations, the fence rail115may, for example, include rectangular tubing (e.g., square tubing). A first fence rail may slide, for example, within a second fence rail. In some implementations, for example, the fence rail115may include an open shape (e.g., an “L-shape” such as angle iron). In the depicted example, the fence rail115is coupled (at opposing ends) to each of the fence posts105with an adaptive fence brace (AFB135). For example, the AFB135may provide flexibility in arranging the connection between the fence post105and the fence rail115. As shown in a close-up diagram depicted inFIG.1, the AFB135includes slots140configured to engage (e.g., mechanically couple) the studs106of the fence post105. In some implementations, the AFB135may include a clamp unit and a bracket to engage the fence post105such that the AFB135is securely fastened to the fence post105. Various implementations of the AFB135are further discussed with reference toFIGS.8-12. In the depicted example, the AFB135includes coupling features145to connect the fence post105with the fence rail115. For example, the coupling features145may receive a fastening bolt146to securely connect to the fence rail115. For example, therefore, the fence post105is securely connected to the fence rail115due to a secure engagement between the fence post105and the AFB135. In various implementations, the AFB135may provide more than one way for engaging the fence post105. Accordingly, the AFB135may, in some examples, advantageously provide flexibility in constructing the ERFBS100. The AFB135also includes coupling features150to diagonally couple to the adjacent fence post105via a tension adjusting rod155. In some implementations, by connecting to the adjacent fence post105, the ERFBS100may have additional reinforcement against rotational force (e.g., ‘torque’ or moment) against the ERFBS100. As shown in this example, the ERFBS100includes a Fence Bracing Gearbox (FBGB165). The FBGB165connects, in this example, two adjacent fence posts105diagonally by coupling the tension adjusting rod155and a coupling member160(e.g., a connecting link). For example, the FBGB165may be used to adjust tension between the fence posts105to advantageously improve reinforcement and stability. In some examples, a tension of the ERFBS100may be reduced after being used for some time due to, for example, weather condition and/or other outside disturbance. For example, the ERFBS100with reduced tension may have reduced strength. In some implementations, the FBGB165may be used to re-adjust the tension between the fence posts105to keep the fence strength at the desired level. In this example, the FBGB165further receives the coupling member160at a fixed length between the fence post105(in connection with the coupling member160) and the FBGB165. As shown in the zoom-in diagram B inFIG.1, the FBGB165receives the tension adjusting rod155though the FBGB165. As shown, a through length170may be allowed through the FBGB165. In some implementations, the FBGB165may adjust a tension between the two adjacent fence posts105by adjusting the through length170. For example, the tension between the fence posts105may be tightened by increasing the through length170. For example, the tension between the fence posts105may be loosened by decreasing the through length170. In some implementations, the FBGB165may further include a locking unit. For example, the locking unit may be a nut threading along the tension adjusting rod155. In some implementations, the locking unit may be tightened against the FBGB165to secure the through length170of the tension adjusting rod155. The ERFBS100includes a tension adjusting brace175. As shown, the tension adjusting brace175may provide a tension adjusting function without using a gearbox. FIG.2AandFIG.2Bdepict an exemplary FBGB165coupled to an exemplary tension adjusting rod155and an exemplary coupling member160, with hook ends (FIG.2A) and engagement ends (FIG.2B). For example, the tension adjusting rod155may be a threaded shaft. For example, the tension adjusting rod155may be connecting on one end to the fence post105. For example, the coupling member160may be connecting diagonally to another fence post. The coupling member160is received at a gearbox housing205. The FBGB165further includes a handle210for operating an internal gear system (not shown). For example, the internal gear system may be used to regulate a relative position of the tension adjusting rod155to the FBGB165. The tension adjusting rod155, in this example, is a fully threaded rod. In other implementations, the tension adjusting rod155may be a partially threaded rod that is threaded at an end portion. In some examples, the tension adjusting rod155may be partially threaded so that it is easy to grip at either end of the tension adjusting rod155. A rod (e.g.,155,160) may be provided with a terminal end (e.g., at a distal end relative to the FBGB165). In the depicted example inFIG.2A, a distal end of the tension adjusting rod155and the coupling member160are each provided with a hook end215. For example, the hook end215may be used to engage a post and/or an AFB135. Accordingly, for example, a user may apply the FBGB as a reusable tensioning tool to apply tension to a fence (e.g., a brace, wire). For example, the user may use the FBGB165to tension the fence, and then apply a diagonal bracing rod, a tension adjusting brace175, wire, and/or cable. In the depicted example inFIG.2B, a distal end of the tension adjusting rod155and the coupling member160are each provided with an engagement end220. The engagement end220, as depicted, may be configured to be coupled (e.g., by a pin, screw, and/or bolt) to an AFB135, for example. For example, the FBGB165may be installed (e.g., permanently, semi-permanently) as an adjustable tension fence bracing module (e.g., diagonal fence brace). The terminal ends (e.g.,215,220) may be releasably coupled to the respective rod(s). For example, a terminal end may be threaded to receive the distal end of the corresponding rod. In some implementations, a terminal end may be fixedly coupled (e.g., welded) to the rod. In some implementations, a terminal end may be pinned to a rod. Some implementations may, by way of example and not limitation, be rotatably coupled (e.g., by a swivel joint such as a swaged swivel joint) to the rod. Implementations with a swivel joint may, for example, advantageously enable repositioning of the FBGB165to a desired orientation for operation. In some examples, various materials may be used to make one or more components. For example, the tension adjusting rod155may be made in aluminum for better durability and less weight. In some examples, the tension adjusting rod155may be made in brass rods for higher corrosion resistivity. Other metal materials, such as steel, titanium, bronze, and/or copper may be used, in some implementations. In some implementations, polymers and/or fiber reinforced polymers (e.g., carbon fiber, fiberglass), for example, may be used. FIG.3is a cross section-view of the FBGB165as described with reference toFIGS.2A-2B. In this example, the FBGB165includes a ring gear305operably coupled to a pinion gear310. For example, a rotation of the pinion gear310may induce a corresponding rotation at the ring gear305. In this example, the pinion gear310operably couple to the handle210. For example, a rotational motion at the handle210may induce rotation at the pinion gear310, which, in turn, may induce rotations at the ring gear305. As shown, the FBGB165includes a threaded lumen315for receiving the tension adjusting rod155. For example, the tension adjusting rod155may be rotatably inserted into the threaded lumen315. In some implementations, at least part of the threaded lumen315may be driven by the ring gear305. For example, the ring gear305may rotate a part of the threaded lumen315to regulate a relative position of the tension adjusting rod155to the FBGB165. The FBGB165includes a bracing chamber320configured to releasably couple to the coupling member160. In some implementations, the bracing chamber320may be threaded to securely receive the coupling member160. In some implementations, the bracing chamber320may include friction inducing material to secure the coupling member160in place. As shown, the bracing chamber320may receive the coupling member160at a substantially parallel axis to the threaded lumen315. The bracing chamber320includes a soft stop unit325. In some implementations, during insertion of the coupling member160into the bracing chamber320, the soft stop unit325may advantageously provide tension relief to avoid damage to the bracing chamber due to excessive tension. In some implementations, the soft stop unit325may be a rubber stop. In some implementations, the soft stop unit325may be a coil spring. FIG.4shows an exemplary gear arrangement of the FBGB165as described with reference toFIGS.2A-2B. In this figure, the housing205is removed for better view of the internal gear system. The ring gear305includes an extended bore405to receive the tension adjusting rod155. For example, the extended bore405may be configured to threadedly engage the tension adjusting rod155. In operation, the handle210may be operated to turn the pinion gear310. The pinion gear310, having an axis of rotation substantially perpendicular to the ring gear305, may induce a rotation at the ring gear305such that the extended bore405may concentrically engage the tension adjusting rod155. For example, the relative position of the tension adjusting rod155to the FBGB165may be altered. In some examples, the tension between the fence posts connected by the FBGB165may be advantageously selectively regulated. In various implementations, during a setup of the ERFBS100, the FBGB165may selectively operate in a sliding mode in which the tension adjusting rod155is permitted to slide in the threaded lumen315along a first longitudinal axis. The FBGB165may operate, in some implementations, in a threading mode in which the ring gear305threadedly couples tension adjusting rod155to the FBGB165. In some examples, the ring gear305may be rotated operably by the handle210to selectively adjust the tension at the FBGB165. After a desired tension is reached, in some implementations, the FBGB165may operate in a locking mode in which the locking unit clamps the tension adjusting rod in a static position relative to the FBGB165. In some implementations, the FBGB165may not include a sliding mode. FIG.5depicts a perspective view of an exemplary tension adjusting brace175. In various examples, the tension adjusting brace175may be used in place of the FBGB165inFIG.1. As shown in, the tension adjusting brace175includes a channel505for receiving the tension adjusting rod155, and a chamber510for receiving the coupling member160. In this example, the tension adjusting brace175further includes a turning member515(e.g., a knob, as depicted). In some implementations, the turning member515may, for example, be configured as a bolt. For example, the turning knob may be operable by a tool (e.g., a wrench). The turning knob may, for example, omit a handgrip in some implementations. FIG.6depicts a cross-section diagram of the tension adjusting brace175as described inFIG.5. As shown, the turning member515has a threaded shaft operably engaging a clamping block605. For example, rotations of the turning member515may induce the clamping block605to move in an axis perpendicular to a longitudinal axis along the channel505. In some examples, when the channel505receives the tension adjusting rod155, the clamping block605may engage and prevent the tension adjusting rod155from sliding. In various implementations, the clamping block605may be threaded to advantageously exert a firm grip on the threaded tension adjusting rod155. In the depicted example, the clamping block605may, be at least partially elastomeric. For example, the clamping block605may include at least one terminal pad610and terminal pad615(e.g., natural rubber, vulcanized rubber, polyurethane). In some implementations, the terminal pad may, by way of example and not limitation, be formed from Shore D 60-80 durometer material. Such a relatively rigid rubber may advantageously resist rotation and/or axial displacement of the tension adjusting rod155when the clamping block605is operated into a locked mode. In some implementations, the terminal pad610may, for example, be a metal (e.g., deformable under a predetermined clamping pressure). The terminal pad610may, for example, be aluminum (e.g., 6010 aluminum), brass, and/or copper. In some implementations, the terminal pad610may, for example, be threaded. The terminal pad615may, for example, regulate a maximum clamping force. A space tolerance between the clamping block605and the corresponding cavity in the brace175may, for example, permit the clamping block605to move axially (e.g., parallel to the channel505) during engagement of the at least one terminal pad610with a (threaded) rod (e.g., to permit threads of the terminal pad610to engage threads of the rod). In some implementations, in a tension adjusting operation, a desired tension may be achieved by sliding the tension adjusting rod155to a desired length relative to the tension adjusting brace175. In some examples, the turning members515can be turned to increase friction between the clamping block605and the tension adjusting rod155. For example, the tension adjusting rod155may be prevented from sliding when the friction is above a (predetermined) threshold. Accordingly, for example, the tension adjusting brace175may provide an alternative option for regulating the tension at the tension adjusting rod. In some implementations, the tension adjusting brace175may advantageously provide a more affordable alternative for diagonally bracing the fence posts105. In some implementations, terminal ends of the rod(s) may be provided with swivel joint(s), such as discussed with respect toFIGS.2A-2B. In such implementations, for example, the terminal ends of the rods may be engaged with opposite ends to be braced (e.g., a first post and a second post). The turning member515may be operated such that the clamping block605is in a sliding mode (e.g., allowing a rod to slide axially through the channel505). For example, a coefficient of friction and/or normal force is below a corresponding predetermined threading threshold Tt. Once the rod is in a desired position, the turning member515may be operated such that the clamping block605is in a threading mode (e.g., engaging the rod such that a coefficient of friction and/or normal force is above the corresponding Tt and below a corresponding predetermined clamping threshold Tc). The rod and/or the brace175may be rotated relative to one another such that the rod is axially translated, relative to the brace175, along a longitudinal axis of the channel505. Accordingly, the rod may advantageously be threaded to apply, for example, a desired tension to the rod(s). Once a desired tension is achieved, the turning member515may be operated such that the clamping block605is in a clamping mode. For example, a coefficient of friction and/or a normal force may be above the corresponding Tc. For example, Tc>Tt. Accordingly, a user may advantageously quickly position a rod in a sliding mode, generate a desired tension in a threading mode, and then clamp the rod in place. FIG.7Ashows an exemplary tension adjusting brace700having two receiving channels705,710. In some implementations, the ERFBS100may include two tension adjusting rods155diagonally coupled to the tension adjusting brace700. In some examples, the tension adjusting brace700may adjust tension of each of the tension adjusting rods155received by adjusting a relative position between the tension adjusting brace700and the corresponding tension adjusting rods155. The tension adjusting brace700further includes two control members715,720. In some implementations, the control members715,720may be a hexagonal socket. For example, the control members715,720may be controlled by inserting and rotating a hexagonal wrench (e.g., an Allen wrench such as a Z-Allen wrench). FIG.7Bshows a cross-section view of the exemplary tension adjusting brace700as described inFIG.7A.FIG.7Cshows an exploded view of the exemplary tension adjusting brace700as described inFIG.7A. In this example, the tension adjusting brace700includes, for each of the channels705,710, clamping blocks725. Each of the clamping blocks725may be used to hold a received tension adjusting rod. Each of the clamping blocks725may be in pressing contact, in this example, with the corresponding control members715,720(depicted as bolts with sockets). In various examples, the spring coil730may be received in a tension relief chamber755such that excess tension is avoided to prevent damage to the tension adjusting rods or the tension adjusting brace700. The spring coil730may, for example, urge the clamping blocks725away from the channels705such that a vertical position of the clamping blocks725is determined by a position of the control members715,720in a block top740(e.g., through a threaded hole, as depicted). As depicted, the block top740is coupled (e.g., releasably) to the body of the brace700by fasteners744(e.g., press-fit, threaded) engaging cavities745(e.g., threaded, sized to pressingly receive the fasteners). A cavity750is configured to (slidingly) receive the clamping blocks725into the body of the brace700. In some implementations, the clamping blocks725may, for example, be configured as disclosed at least with reference to the clamping block605. In some implementations, for example, the clamping blocks725may include corresponding rubber pads. In some implementations, such as depicted, the clamping blocks725may include a threaded block735. The threaded block735, as depicted, includes a threaded end configured to selectively engage a threaded rod operated through a corresponding lumen (e.g., channels705,710) in response to operation of the control members715,720. In some implementations, in operation, when the control member715is rotated and driven towards the channels705, the spring coil730may be pressed towards the clamping block725. For example, when a tension adjusting rod is received at the channel705and the control member715is rotated towards the channel, the tension adjusting rod may be secured at a desire position at the tension adjusting brace700. FIG.8depicts a perspective view of an exemplary adaptive fence brace (AFB)135bracing a fence post105. As shown, the AFB135includes a butterfly clamp805and a C-bracket810. In this example, the butterfly clamp805is installed on the blade side of the fence post105. The C-bracket810is installed on the opposite side, the stud side of the fence post105. As shown, a corresponding side wall815of the C-bracket810extends from each side in the same direction as a blade820of the fence post105in this configuration. The body of the fence post105is, as shown in this example, sandwiched between the butterfly clamp805and the C-bracket810. In this example, the butterfly clamp805and the C-bracket810are fastened to each other and consequently to the fence post105using bolts825a,825b(e.g.,825bmay have a larger diameter than825a, such as corresponding to a diameter of the corresponding aperture). As shown, the fence post105includes studs830that protrude through the slots140when the AFB135is secure at the fence post105. FIG.9depicts a perspective view of an exemplary butterfly clamp805. In this example, the butterfly clamp805includes a rib receiving channel905. For example, the rib receiving channel905may receive a ridge portion of a T-post along a longitudinal axis. From the rib receiving channel905, the butterfly clamp805includes two side walls815. In this example, the side walls815include two pairs of horizontally aligned first apertures915. In some implementations, the first apertures915may be registered, in use, with a bracket to securely couple to a T-post. The side walls815further includes one pair of horizontally aligned second apertures920, in this example. In some implementations, the second aperture920may be larger than the first aperture915. For example, the second aperture920may be used to couple with the tension adjusting rod155and/or the coupling member160. In this example, the butterfly clamp805further includes an adaptive facing925between the rib receiving channel905and each of the side walls815. In some implementations, the adaptive facing may provide room for adaptively coupling to fence posts of different sizes and thickness. FIG.10depicts a perspective view of an exemplary C-bracket810. The C-bracket810includes a back wall1105. The back wall1105may, as shown in this example, engage a stud side of the fence post105. In this example, the C-bracket810includes two slots140for receiving the studs830of the fence post105. The C-bracket810also includes, in this example, first apertures1005and second apertures1010for registering with the butterfly clamp805. For example, studs of a T-post may protrude through the slots140. The back wall1105includes two pair of horizontally aligned first apertures1005. In some implementations, the first apertures1005may be registered to the first apertures915of the butterfly clamp805. The back wall1105further includes one pair of horizontally aligned second apertures1010, in this example. In some implementations, the second aperture1010may be larger than the first aperture1005. For example, the second aperture1010, together with the second aperture920, may be used to securely couple with the tension adjusting rod155or the coupling member160. In the depicted example, the C-bracket810includes side walls815extending perpendicularly from the upper ⅔ of the back wall1105. In some implementations, each of the side walls815may include horizontally disposed (two) sets of transversely opposed apertures1115for fastening devices. In various implementations, transversely opposed apertures1115may be used to couple the fence posts105to the fence rails115. In some implementations, the butterfly clamp805may also be coupled to a bracket that is a flat plate having features as described as the back wall1105. In some implementations, a combination of the apertures920, t h e corresponding apertures1010, and bolts825a,825bwith accompanying nuts1205a,1205bmay be dual purpose. For example, the combination may be used to fasten the tension adjusting rod155and the coupling member160to the AFB135in addition to reinforcing the corresponding brackets to the fence posts105. FIG.11shows a top view of an exemplary AFB135. As shown in this example, when the butterfly clamp805and the C-bracket are combined, the AFB135includes a pinch gap1305created by the adaptive facing925of the butterfly clamp805. Accordingly, the AFB135may advantageously adapt to fence post105of various size and thickness. FIG.12shows a second exemplary arrangement of an exemplary AFB135combining the butterfly clamp805ofFIG.9, the C-bracket810ofFIG.11, and the fence post105. As shown, the butterfly clamp805, the C-bracket810, and the fence post105are fastened in a similar manner as described inFIG.8. As shown, the C-bracket810is fastened to the butterfly clamp805with the bolts825a,825band nuts1205a,1205b. In this example, the side walls815extends in the opposite direction as the blade820. FIG.13A,FIG.13B, andFIG.13Cillustrate top plane views of an exemplary AFB135arrangements having one end of a fence rail115installed at various locations of the AFB135. Referring toFIG.13A, the fence rail115at one end is installed in between the side walls815of the C-bracket810. As shown, a fastening bolt1505traverses through a pair of apertures1115a,1115bon the side walls815, and through apertures of the fence rail115. For example, the fastening bolt1505is secured with an internally threaded nut1510threaded over the externally threaded segment of the fastening bolt1505. Referring toFIG.13B, the fence rail115is installed on an outside of one of the side walls815of the C-bracket810. In this example, the side walls815(e.g., sidearms) are on a stud side of the fence post105. As shown, the fastening bolt1505traverses an aperture on the fence rail115and the apertures1115on the side walls815. For example, the fastening bolt1505is secured with an internally threaded nut1510threaded over an externally threaded segment of the fastening bolt1505. Referring toFIG.13C, the fence rail115is installed in between the side walls815. As shown in this example, the side walls815are on the blade side of the fence post105. In this case, the fastening bolt1505may, for example, traverses an outer set of the apertures1115of the side walls815. FIG.14A,FIG.14B,FIG.14C, andFIG.14Dshow top plane views of exemplary AFBs135that couple two fence rails115. Referring toFIG.14A, the AFB135is coupled to another C-bracket810b, creating an extended AFB1600having a combination of C-brackets810a,810b. In some examples, either side of the AFB1600may have side walls815available for fastening the fence rails115. As shown in this example, a first fence rail115ais fastened at the C-bracket810a, and a second fence rail115bis fastened at the C-bracket810b. Referring toFIG.14B, the fence rails115a,115bare installed on the outside of the side walls815of the AFB135. A fastening bolt1605, in this example, traverses the fence rail115a, the inner set of the apertures1115, and the fence rail115b. In this example, the fastening bolt1605is secured with a nut1610. A similar installation of fence rails on the AFB135is shown inFIG.14C. The fence rails115a,115b, as shown in the example shown inFIG.14C, are installed on the outside of the side walls815of the AFB135. A fastening bolt1605, in this example, traverses the fence rail115a, the outer set of the apertures1115, and the fence rail115b. In this example, the fastening bolt1605is secured with a nut1610. To brace corners and T-junctions of fences, the fence rails115, in some implementations, may be installed perpendicular to each other. As shown inFIG.14D, the AFB135is installed on a corner fence post. The fence rail115a, for example, may be fastened on the outside of the side walls815. The fence rail115bmay be fastened in between the sidearms, for example. A fastening bolt1605may, in some implementations, traverse an end of the fence rail115a, the aperture1115a, a side of the fence rail115b, and the aperture1115b. The fastening bolt1605may be secured with the nut1610, for example. FIG.15A,FIG.15B, andFIG.15Cshows exemplary applications of ERFBS100with wood posts, T-posts, and a combination thereof. For example,FIG.15Adepicts a corner fence brace1501constructed using fence post105(t-posts, as depicted). In various implementations, adjacent fence posts105may be diagonally braced by either one or two tension adjusting rods. As shown inFIGS.15B-15C, a brace may be constructed at least partially using a wood post1505. For example, corner fence brace1502depicts a corner wood post1505coupled to two t-posts (fence post105). Corner fence brace1503depicts three wood posts1505. As depicted, a tension adjusting rod may be coupled to the wood post1505(e.g., instead of using the AFB135), via a coupling feature of the fence rail115. For example, a coupling member1510may be embedded in the wood post1505. The coupling member1510may, for example, be a bolt fastened through a hole drilled in the wood post1505. In some embodiments, an end of the tension adjusting rod (e.g., coupled to the brace175and/or the brace700) may be directly coupled to the coupling member1510(e.g., instead of being coupled to the fence rail115). In some examples (not shown), an AFB135may be coupled to the wood post1505(e.g., through first apertures1005and/or second apertures1010). The fence rail115and/or a tension module (e.g., brace175, brace700) may be coupled to the wood post1505via the AFB135. FIG.16AandFIG.16Bdepict exemplary bracing rails. As depicted inFIG.16A, the fence rail115is assembled from an inner rail125and an outer rail120. In the depicted example, the inner rail125and the outer rail120each have a substantially rectangular cross-section (e.g., a square cross-section, as depicted). The inner rail125is configured to be slidingly received within the outer rail120. The inner rail125is provided with a first set of apertures1820distributed along the longitudinal axis of the inner rail125. The outer rail120is provided with a second set of apertures1825distributed along the longitudinal axis of the outer rail120. When the longitudinal axes of the inner rail125and the outer rail120are aligned and the inner rail125and the outer rail120are slid together to a desired length such that at least one of the first set of apertures1820is aligned with a at least one of the second set of apertures1825, a coupling member130(e.g., a bolt and nut, a pin) may be coupled through the corresponding apertures to fix the fence rail115at a desired length. In the depicted example, the inner rail125and the outer rail120each are provided with an aperture1835aat a distal end. For example, the aperture1835amay be used to fasten the distal end of the rail to a post (e.g., directly, by a bolt, to an AFB135). An aperture1815may, for example, be configured to provide access into an interior of the rail to reach an inner side of the distal end (e.g., to reach the inside of the aperture1835a). The aperture1815may, for example, advantageously provide access to fasten a bolt, nut, and/or other coupling member. In the depicted example, the inner rail125and the outer rail120are each provided with at least one aperture1835bjust proximal of the distal end. For example, the at least one aperture1835bmay be used to couple the fence rail115to a host (e.g., a post, an AFB135, an anchor in a wood post). As depicted, the inner rail125and the outer rail120are each provided with a coupling member1840(e.g., a tab with a hole, as depicted) extending substantially orthogonally from the longitudinal axis. The coupling member1840may, for example, couplingly receive (e.g., by a bolt, a pin, a rivet) an end of a diagonal bracing rod (e.g., engagement end220of the FBGB165, rod155and/or coupling member160of the brace175and/or brace700. As depicted inFIG.16B, the fence rail115is assembled from a first rail1850and a second rail1855. In the depicted example, the first rail1850is provided with a first set of apertures1860. The second rail1855is provided with a second set of apertures1865. In the depicted example, the apertures1865each extend (e.g., as slots) in a first direction substantially parallel to a longitudinal axis of the fence rail115. The apertures1860each extend (e.g., as slots) in a second direction substantially orthogonal to the longitudinal axis of the fence rail115. When the first rail1850and the second rail1855are brought into alignment such that their corresponding longitudinal axes are substantially aligned, the first rail1850and the second rail1855may be coupled together by at least one coupling member130being coupled through corresponding apertures of the first set of apertures1860and the second set of apertures1865. As depicted, by the apertures1860and the apertures1865extending in different direction (e.g., substantially orthogonal to each other, as depicted), a user may easily align the apertures to insert the at least one coupling member130through them. The slots may, for example, advantageously enable the apertures to be aligned regardless of offset in the holes due to a thickness of the first rail1850and the second rail1855. For example, the slots may allow the first rail1850and the second rail1855to be interchangeably used as an inner or outer rail (e.g., nested inside each other with either one being able to be nested inside the other and/or sitting over the other). Although various implementations have been described with reference to the figures, other implementations are possible. In some implementations, the FBGB165may include various gearing ratio. For example, the ring gear305and the pinion gear310may have a 1:1-3:1 ratio. In some implementations, a worm gear may be used at the FBGB165. The worm gear may, for example, be a reducing gear. In some implementations, the FBGB165may include a self-braking system. For example, when the tension at the tension adjusting rod155is above a threshold, the FBGB165may automatically stop length adjustment of the tension adjusting rod. For example, the self-braking system may avoid over tension of at the FBGB and protect the fence from damage. In some implementations, a reducing worm gear (e.g., driving the ring gear305, such as in place of the pinion gear310) may be configured as the self-braking (e.g., self-locking) system. For example, the worm gear may prevent rotation of the ring gear305in response to tension applied to the threaded rod. Some such implementations may, for example, not have stop blocks. In some implementations, torque transmission may be provided by the ring gear305and the pinion gear310, such as depicted in the corresponding figures. In some examples, the ring gear305and/or a drive gear (e.g., the pinion gear310) may be configured as a bevel gear. A gear may, for example, be implemented as a spur gear. Some implementations (e.g., of the FBGB165) may include a stop block(s). For example, the stop block may be configured as a self-braking mechanism. In some implementations, the stop block may be configured as a manually-activated braking mechanism. The stop block may, for example, clamp against a rotating member (e.g., a gear, the threaded rod) to prevent rotation of the threaded rod in response to tension. Some implementations may, for example, omit the stop block(s). In some implementations, a clamping block (e.g.,605,725) may be configured as a floating block. For example, the floating block may be positioned within a cavity in the corresponding body (e.g.,175,700) that is larger in at least one dimension. The floating block may, therefore, have room to ‘float’ along at least one axis such that the block may align with a threaded rod (e.g., to matingly align threads when being operated into a threading or clamping mode from a sliding mode). Terminal pads (e.g.,615) may, for example, be provided within the cavity to provide a (predetermined) minimum friction, prevent ‘rattling’ and/or reduce ‘slop’ (e.g., when the block is clamped such as by515,715, and/or720). In some implementations, the pinion gear310may be driven by a hexagonal socket. For example, the pinion gear310may be operated by inserting an Allen wrench into the hexagonal socket. Although an exemplary system has been described with reference toFIG.1, other implementations may be deployed in other industrial, scientific, medical, commercial, and/or residential applications. In an illustrative aspect, a post brace bracket may include a butterfly clamp. The butterfly clamp may include a rib-receiving channel configured to receive a first longitudinal rib of a fence post. The fence post may extend along a longitudinal axis. The butterfly clamp may include tabs extending from corresponding proximal edges of the rib-receiving channel and configured to register with a second longitudinal rib of the fence post. The first longitudinal rib and the second longitudinal rib may intersect in a plane orthogonal to the longitudinal axis. The post brace bracket may include a receiver bracket. The receiver bracket may include a first wall including a fastening aperture configured to receive at least one stud extending from a face of the second longitudinal rib. The receiver bracket may include two side walls extending from opposite edges of the first wall and each comprising a coupling aperture configured to releasably couple to a lateral rail. When the butterfly clamp and the receiver bracket are coupled together at either side of the first wall, the fastening aperture may engage the at least one stud to resist translation parallel to the longitudinal axis and the rib-receiving channel may engage the first longitudinal rib to resist rotation about the longitudinal axis. When the butterfly clamp and the receiver bracket are coupled together, the two side walls may be configured to releasably couple to multiple lateral rails, such that each of the multiple lateral rails extends substantially orthogonally away from the fence post. The proximal edges of the rib-receiving channel may include an offset bridge connecting a horizontal plane of the tabs and a plane of the proximal edges such that, when the butterfly clamp and the receiver bracket are coupled together to brace a fence post, the offset bridge and the first wall of the receiver bracket create an adaptive space configured to fit multiple shapes of the fence post. The post brace bracket may include a second receiver bracket coupled to the receiver bracket. The two side walls may each extend from substantially two-thirds of the corresponding proximal edges of the first wall. The two side walls may include more than one pair of coaxially aligned coupling apertures to releasably couple to a lateral rail. In an illustrative aspect, a tensioning module may include a channel defining a lumen having an aperture at a distal end and configured to slidingly receive a threaded rod through the channel such that the threaded rod extends along a first longitudinal axis. The tensioning module may include a coupling member at a proximal end configured to couple to a connecting link extending along a second longitudinal axis substantially parallel to the first longitudinal axis. The tensioning module may include a ring gear concentrically and at least partially threadedly coupled to the threaded rod such that, when the ring gear is rotated, the threaded rod is induced to move along the first longitudinal axis. The tension module may include a second gear operably coupled to the ring gear and having an axis of rotation perpendicular to that of the ring gear. The second gear may be configured such that, when the second gear is rotated in a first rotational direction, the second gear induces a rotational motion of the ring gear about the threaded rod such that a position of the threaded rod relative to the tensioning module is altered. The second gear may include a pinion gear. The second gear may include a worm gear. The tensioning module may include a lever arm configured to induce rotation of the second gear when the handle is operated by a user. The lever arm and include a handle releasably coupled to the second gear. The ring gear may be mounted to a housing by at least one rolling bearing. The coupling member may include a threaded channel configured to receive the connecting link such that a position of the connecting link relative to the channel is adjustable. In an illustrative aspect, a tensioning module may include a body including a channel defining a lumen having an aperture at a distal end of the body and extending substantially through the body. The channel may be configured to slidingly receive a tension adjusting link through the channel such that the tension adjusting link extends along a first longitudinal axis. Tensioning module may include a coupling feature at a proximal end of the body. The coupling feature may be configured to couple to a connecting link extending along a second longitudinal axis substantially parallel to the first longitudinal axis. Tensioning module may include a tension regulation module configured to selectively engage the tension adjusting link with the tensioning module. The tension regulation module may be selectively operable between: a sliding mode in which the channel is configured to permit the tension adjusting link to slide in the lumen along the first longitudinal axis, and a tension adjusting mode in which the tension regulation module performs tension adjusting operations to the tension adjusting link such that a position of the tension adjusting link relative to the tensioning module is altered such that a tension between a proximal end of the connecting link and a distal end of the tension adjusting link is adjusted. The tension adjusting link may include a threaded rod. The tension adjusting mode may be a threading mode in which the tension regulation module threadedly engages the threaded rod in the channel. In the tension adjusting mode, the tension adjusting operation may include threadedly couple the threaded rod and the tension regulation module. The tension regulation module may include a clamping block configured to selectively engage the tension adjusting link. The tension regulation module may include a tension application unit operably coupled to the clamping block such that, when a force perpendicular to the first longitudinal axis is applied, the clamping block engages the tension adjusting link to regulate the position of the tension adjusting link relative to the tensioning module. The clamping block may include a threaded surface configured to threadedly engage the tension adjusting link. The clamping block may include an elastomeric end module. The elastomeric end module may be configured with a durometer rating of at least Shore D 60. The tensioning module may include a locking module. The tensioning module may be further selectively operable in a locking mode in which the locking module clamps the tension adjusting link in a static position relative to the tensioning module. The coupling feature may include a connecting link receiving end module configured to relieve excess tension to the tensioning module. The coupling feature may include a coil spring. The tension regulation module may be further configured to selectively engage the connecting link such that a tension of the connecting link and a tension of the tension adjusting link are independently adjustable. The coupling feature include a threaded channel to receive the connecting link such that a position of the connecting link relative to the channel is adjustable. The tension regulation module may further include a miter gear releasably coupled to the threaded rod. An illustrative aspect, an adaptable fence bracing rail may include a first rail extending along a first longitudinal axis. The first rail may include a first aperture at a distal end. The first rail may include a first plurality of apertures in a wall of the first rail distributed along at least a portion of the first rail in a first line substantially parallel to the first longitudinal axis. The adaptable fence bracing rail may include a second rail extending along a second longitudinal axis. The second rail may include a second aperture at a distal end. The second rail may include a second plurality of apertures in a wall of the second rail distributed along at least a portion of the second rail in a second line substantially parallel to the second longitudinal axis. The first rail and the second rail may be configured such that, when the first rail and the second rail are brought into register such that the first longitudinal axis and the second longitudinal axis are substantially aligned, and at least one coupling member passes through at least one of the first plurality of apertures and at least one of the second plurality of apertures to couple the first rail to the second rail, then the first rail and the second rail are coupled into a field-adjustable bracing rail wherein the distal end of the first rail and the distal end of the second rail form opposite ends of the field-adjustable bracing rail. The field-adjustable bracing rail may be configured to be coupled to a first post by the first aperture and a second post by the second aperture such that the field-adjustable bracing rail resists compressive force induced by motion of the first post and the second post towards each other. At least one of the first aperture and the second aperture may be configured to couple the corresponding end of the field-adjustable bracing rail to a bracket coupled to a post in a predetermined orientation to the post. The first plurality of apertures may include slots extending substantially parallel to the first longitudinal axis. The second plurality of apertures may include slots extending substantially orthogonal to the second longitudinal axis. At least one of the first rail and the second rail may be substantially defined by an L-shaped cross-section. At least one of the first rail and the second rail may be substantially defined by a closed cross-section. The closed cross-section may be substantially rectangular. At least one of the first rail and the second rail may be configured to slidingly assemble into the other of the first rail and the second rail. The adaptable fence bracing rail may include a coupling member extending substantially orthogonally from at least one of the first longitudinal axis and the second longitudinal axis. The coupling member may be configured to releasably couple to a diagonal tension member. A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made. For example, advantageous results may be achieved if the steps of the disclosed techniques were performed in a different sequence, or if components of the disclosed systems were combined in a different manner, or if the components were supplemented with other components. Accordingly, other implementations are contemplated within the scope of the following claims. | 48,658 |
11859401 | DETAILED DESCRIPTION The illustrated embodiments are disclosed with reference to the drawings. However, it is to be understood that the disclosed embodiments are intended to be merely examples that may be embodied in various and alternative forms. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. The specific structural and functional details disclosed are not to be interpreted as limiting, but as a representative basis for teaching one skilled in the art how to practice the disclosed concepts. Referring toFIGS.1-4, a fence10is disclosed, that includes a frame12that is erected on-site by assembling a top rail14, a bottom rail16, and intermediate rail18, a right-side rail20, and a left-side rail22. The rails14-22are either welded or assembled with fasteners and are made of metal such as steel or aluminum. The intermediate rail18is parallel to, and spaced from the top rail14and the bottom rail16. The intermediate rail18extends horizontally and is attached to the right-side rail20and the left-side rail22. A modular fence panel24is pre-assembled off-site iii a manufacturing facility that includes a plurality of plastic planks26(planks). The planks26have a front side28and a rear side30that are assembled in a planar arrangement. The planks26have top ends32and bottom ends34that are aligned when the planks are assembled. With particular reference toFIG.2, an intermediate bar36is an L-shaped angle bar that is assembled at an intermediate location38on the planks with fasteners. The intermediate bar36holds the planks26together (other reinforcements or supports, such as the top angle bar72and the bottom angle bar74, may be used to hold the modular fence panel together, or alternatively a transverse connector may be provided as shown inFIGS.9&10, to form the modular fence panel24that is transported to the site as a modular fence panel24. The modular fence panel24is then assembled to the frame12by attaching the intermediate bar36to the intermediate rail18with fasteners. With particular reference toFIG.4, a top bracket40defines a channel42that is adapted to receive both the top rail14and the top end28of the planks26. In the embodiment ofFIGS.1-4, the channel42has a downwardly facing pocket44and is attached to the top end32of the planks26. The top bracket40is attached to the planks26with fasteners. A top gap46is defined between a top wall48of the top bracket40and the top rail14. The spacing between the intermediate bar36and the top bracket40sets the gap44to allow for expansion and contraction of the upper portion of the planks26. With particular reference toFIG.3, a bottom bracket50defines a bottom channel52that defines an upwardly facing pocket54that is adapted to receive the bottom ends34of the planks26. The bottom ends34of the planks26are fastened to the upwardly facing pocket54of the bottom bracket50. The bottom bracket50also includes a downwardly facing pocket56that is hooked over the bottom rail16with a bottom gap58being defined between the bottom rail16and a base wall59of the downwardly facing pocket56. The spacing between the intermediate bar36and the bottom bracket50establishes the bottom gap5$ that accommodates expansion and contraction of the lower portion of the planks26. Referring toFIG.5, a fragmentary top plan view of a portion of the intermediate rail18and the intermediate bar36is provided to show how the intermediate bar36is fastened to the intermediate rail18. A slot61is provided on the intermediate bar36that receives fasteners62(e.g., carriage bolts). The slot61provides relief for positioning the intermediate bar36laterally on the intermediate rail18. The planks26are fastened to the intermediate bar36by fasteners63to secure the planks on the intermediate bar36. Referring toFIGS.6-9another embodiment of the fence70is illustrated that differs from the embodiment, ofFIGS.1-4in that a top angle bar72is attached to the top rail14, a bottom angle bar74is attached to the bottom rail16. and an intermediate angle bar76is attached to the intermediate rail18. The angle bars have two w all: that meet at a 90-degree angle. A vertical wall78is attached flush to the planks26and a horizontal wall80extends perpendicularly from the back side30of the planks26. The top angle bar72is attached with shoulder screws82to the top rail14with clearance between the shoulder screws82and an opening84defined by horizontal wall80of the top angle bar72. The bottom angle bar74is attached with shoulder screws82to the bottom rail16with clearance between the shoulder screws82and an opening86defined by the horizontal wall80. The clearances are provided to accommodate thermal expansion of the planks26by allowing the upper and lower angle bars to move in a vertical direction relative to the length of the shoulder screws82through the openings84and86. The shoulder screws82are fixedly attached to the rail14and the L-shaped bars are allowed to move vertically due to thermal expansion and contraction. The angle bar72has clearance slots or holes where they receive the shoulder screws82. Shoulder screws82are preferred because access to the tip of the shoulder screws is difficult inside the rails. Referring toFIG.7, one of the planks26is shown o be attached to the intermediate angle bar76by fasteners62. The horizontal wall80of the intermediate angle bar76is fixedly attached with a carriage bolt88to the intermediate rail18with the carriage bolt88being received in a hole90defined by the horizontal wall80and in a hole92defined by the top wall and bottom wall of the intermediate rail18. The carriage bolt88extends completely through and is fastened with a nut to fixedly attach the intermediate angle bar76to the intermediate rail18. Referring toFIG.8, one of the planks26is shown to be attached to the bottom angle bar74by fasteners93. The horizontal wall80of the bottom angle bar74is retained on the bottom rail16with the shoulder screws82being received in the opening86defined by the bottom angle bar74and screwed into bottom rail16. A clearance100is defined between the shoulder screws82and the opening86that is a sufficient clearance to allow the angle bar74to be raised and lowered by thermal expansion of the planks26. (e.g., 2.0 to 3.0 mm.) The shoulder screws82are attached to the bottom rail16with an upper gap94defined between the head98of the shoulder screw82and the horizontal wall80and a lower gap100being defined between the horizontal wall80and the bottom rail16. As the planks26expand or contract in the vertical direction, the bottom ends34of the planks and angle bar74can move vertically relative to the bottom rail16. A bottom trim piece102is attached to the bottom end of the planks26. The trim piece102may be assembled between the bottom angle bar74and the plank26and is held in place by the fasteners93. Referring toFIG.9, one of the planks26is shown to be attached to the top angle bar72by fasteners104. The horizontal wall80of the top angle bar72is retained on the top rail14with the shoulder screws82being received in the opening84defined by the top angle bar72. The shoulder screws82are screwed into the top rail14. A clearance is defined between the shoulder screws82and the opening84that is a sufficient clearance to allow the top angle bar72to be raised and lowered by thermal expansion of the planks26, (e.g., 2 to 3 mm.) The shoulder screws82are attached to the top rail14with an upper gap94defined, between the horizontal wall80and the bottom rail16. A lower gap100is defined between the head98of the shoulder screw82and the horizontal wall80. As the planks26expand and contract in, the vertical direction, the top end of the planks26can move vertically relative to the bottom rail16. The fence includes a frame that is substantially the same as the frame described with reference toFIGS.1-9that includes the frame12that is pre-assembled by assembling a top rail14, a bottom rail16. and intermediate rail18, a right-side rail20, and a left-side rail22. The rails14-22are preferably welded but may be assembled with fasteners. The frame rails are, made of metal, such as steel or aluminum. The intermediate rail18is parallel to, and spaced from the top rail14and the bottom rail16. The intermediate rail18extends horizontally and is attached to the right-side rail20and the left-side rail22. The right-side rail20and left-side rail22may include portions that extend below the bottom rail16thereby raising the height of the fence. The portions extending below the bottom rail16may be provided with escutcheons to facilitate attaching the fence110to a concrete mounting surface or may be embedded in the ground or other foundation. Referring toFIG.10, an alternative embodiment of a fence110is illustrated that is made up of plastic planks112that are assembled in modules114of3or4planks but could be modules including 5 or more planks112. Though not preferred, the fence could be made up of single planks112. The planks112as illustrated are viewed inFIG.10showing their front side116. The planks each have a top end118and a bottom end120. The bottom ends120of the planks112are attached to the bottom transverse connector122. A bottom L-shaped trim piece124is shown, in part, that is attached to the bottom rail16. The bottom L-shaped trim piece124covers the bottom ends120of the planks112. The bottom ends120of the planks112are free to move relative to the trim pieces124and the bottom rail16to accommodate expansion and contraction of the planks112. As illustrated inFIG.10, the bottom of the left side plank112and the L-shaped trim piece are fragged away to better show the bottom transverse connector122in relation to the bottom rail16 Referring toFIG.11, the bottom L-shaped trim piece124is attached to the bottom rail16with fasteners125. The bottom L-shaped trim pieces124include a horizontal leg124′ that is attached to a bottom surface of the bottom rail and a vertical leg124″ that extends in front of the front side116of the planks112. The horizontal leg124′ the vertical leg124″ are joined at a slight angle of about 87° to 89° in the free state to apply a lateral load to the front side116of the planks112near the bottom ends120. A top transverse connector126is attached to the top end118of the planks to assemble the top end of the module114that includes several planks. A top L-shaped trim piece is attached to the top rail14preferably on a top surface thereof with a fastener130. The top L-shaped trim piece128is attached to the top rail14with fasteners130. The top L-shaped trim pieces128include a horizontal leg128′ that is attached to a top surface of the top rail14and a vertical leg128″ that extends in front of the front side116of the planks112. The horizontal lee128′ the vertical leg128″ are joined at a slight angle of about 87′ to 89° in the free state to apply a lateral load to the front side116of the planks112near the top ends118. The trim piece is preferably assembled off-site when the frame12is assembled to minimize assembly operations in the field where the fence110is to be erected. InFIG.11the back side132of the planks112is shown in relation to the top transverse connector126. The top ends of the planks118. and the top L-shaped trim piece128. The top transverse connector126and the bottom transverse connector122in addition to connecting the planks112together to form the modules114also function as spacers that space the top ends118and bottom ends120from the frame12. An intermediate transverse connector134is attached at an intermediate location136on the planks on the planks112at the same level as the intermediate rail18. The planks112define a hole138that is aligned with a hole140defined by the intermediate transverse connector134. A pair of holes142are defined in the spaced walls of the intermediate rail18. A nut and bolt144is assembled through the holes138,140, and142and secured with a nut that is tightened to securely fasten the planks112to the intermediate transverse connector, and the intermediate bar. As described with reference toFIG.10and as also shown inFIG.11, the bottom ends of the planks112are connected by the bottom transverse connector122to form the modules114. The modules114can be transported with the frame12and the desired number of modules114to the site where the fence is to be installed with the frame12preassembled. The modules114are longer than the space between the top L-shaped trim piece128and the bottom L-shaped trim piece but shorter than the space between the horizontal leg124′ of the bottom L-shaped trim piece and the horizontal leg128′ of the L-shaped trim piece128. To assemble the modules114to the frame12, the modules are bent lengthwise to clear the vertical, legs124″ and128″ and are received between the vertical legs and the frame12. The bolt144is inserted through the holes138,140, and142and secured with the nut to secure the modules114to the frame12. A top gap146is defined between the top end118of the planks112and the horizontal leg128of the L-shaped trim piece128. A bottom gap148is defined between the bottom end120of the planks112and the horizontal leg124′ of the L-shaped trim piece124. Referring toFIG.13. the planks are shown to be of the tongue152and groove154type. The vertical edges of the planks112are fit together with the tongues152being inserted in the grooves154to eliminate any gaps between the planks112. The embodiments described above are specific examples that do not describe all possible forms of the disclosure. The features of the illustrated embodiments may be combined to form further embodiments of the disclosed concepts. The words used in the specification are words of description rather than limitation. The scope of this disclosure is broader than the specifically disclosed embodiments and also includes modifications of the illustrated embodiments. | 13,871 |
11859402 | DETAILED DESCRIPTION OF THE INVENTION The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms “a”, “an”, and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise; for example, fluid pathway can mean either a single pathway or multiple pathways. It will be further understood that the terms “comprises” and/or “comprising”, or “includes” and/or “including”, or “have” or “having”, when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components and/or groups thereof. For the sake of simplicity and to give the claims of this patent application the broadest interpretation and construction possible, the conjunctive “and” may also be taken to include the disjunctive “or,” and vice versa, whenever necessary to give the claims of this patent application the broadest interpretation and construction possible. Likewise, when the plural form is used, it may be taken to include the singular form, and vice versa, whenever necessary to give the claims of this patent application the broadest interpretation and construction possible. It will be understood that, although the terms first, second, third, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another element. Likewise, synonyms for the same element, term or concept may be used only to distinguish one similar element from another, unless the context clearly indicates otherwise. The terms “fastener”, “fastening means” and the like are intended to be non-limiting. For examine, those terms may mean a bolt including a threaded end receiving a nut, a pin having an end with a transverse bore therethrough for accepting a cotter pin or other type of pin, a pin having a transverse bore at one end having one end of an essentially U-shaped metal coupler threaded therethrough and with the other end of the U-shaped coupler capturing the opposite end of the pin, or any arrangement of structure(s) capable of fastening/connecting at least two other structures, either permanently or temporarily as indicated from the context of usage. The disclosure herein is not limited by construction materials to the extent that other materials satisfy the structural and/or functional requirements. For example, any material may be used so long as it satisfies the functional and structural requirements for which it is being used. In one embodiment, the components of the apparatus are constructed of steel or other structural metallic material; however, any material may suffice as well, if it satisfies the functional and structural requirements for which it is being used. Likewise, the disclosed invention is not limited by any construction process or method. In general, the invention disclosed herein includes (comprises) an apparatus expandable from a compact transport configuration to a free-standing use configuration for positioning a fence post essentially vertically to allow the user to manually drive it into the ground. In one general embodiment, the apparatus includes a compactable tri-pod-like assembly including an assembly head having means for connecting the legs. Connecting to the assembly head (40) are:(1) a pair of pivotable 1st and 2nd support legs (10and20), each having a foot end (18and28) and having an apex end (11and21) pivotably connected to the assembly head and essentially opposing the apex end of the other support leg;(2) a 3rd pivotable support leg (30) having a 3rd foot end (38) and a 3rd apex end (31) pivotably connected to the assembly head and enabling the apparatus to stand when all three support legs are pivoted outwardly; and(3) a stabilizer support (50) downstanding from the assembly head, and comprising a lower connection end (57). For bracing the tri-pod and holding the post in an essentially vertical orientation awaiting driving, there is also a stabilizer guide member (60) comprising:(1) a middle portion (66) pivotably connected to the lower connection end (57) of the stabilizer support;(2) a stabilizer end (64) pivotably connected to the 3rd support leg; and(3) an opposite guide end (68) defining an aperture (69) sized to accept insertion of the unclaimed fence post in a manner positioning it essentially vertically for commencement of the user manually driving it into the ground but facilitating lifting of the apparatus off the partially driven post without altering the vertical positioning thereof. In one specific embodiment of the invention, the apparatus described herein includes the pivotable 1st and 2nd support legs oriented to pivot apart in substantially the same plane. The 3rd pivotable support leg may then be oriented to pivot outwardly in a plane essentially perpendicular to the plane of the pivotable 1st and 2nd support legs. The assembly head may further comprise a pair of essentially parallel front and back support plates (41and46), each support plate including a lower hole (43and48) aligned with a corresponding lower hole of the other support plate. Each of the pivotable 1st and 2nd support leg's apex ends may have a cross-sectional area defined by the outer surfaces, and each apex end of the respective 1st and 2nd support legs may further comprise a converging tip region (12and22) including a terminal tip (14and24). One surface of the support leg may also include a diagonal planar cutaway (13and23), reducing the cross-sectional area as the tip is approached, thereby essentially converging the apex end of the support leg into a narrowing tip end. The apex end of each respective support leg also includes a lower bore (16and26) aligned with the aligned lower holes of the front and back support plates; each respective lower bore and lower holes receive a hinge pin (51and52) enabling the support leg to pivot from a vertical compacted position outwardly to a free-standing use position. The pair of essentially parallel front and back support plates may further include an upper hole (42and47) aligned with a corresponding upper hole of the other support plate. Each of the converging tip regions of the respective pivotable 1st and 2nd support legs may further include an upper bore (15and25) aligned with the upper holes and near the tip, and situated along a plane closely parallel to the diagonal planar cutaway. Each respective upper bore and upper holes may receive a removable fastening pin so that, when a support leg is in the vertical compacted position, the upper holes of the opposing support plates are aligned with the upper bore near the tip, so that inserting the fastening pin therethrough locks the leg in the compacted position; on the other hand, inserting the fastening pin through the upper holes in the support plates when the leg is in the free-standing position chocks against the outer surface of the leg near its tip, to fix the leg in the free-standing position. The removable fastening pin may also include a fastener end configured to accept a removable fastener. The removable fastener may be selected from the group consisting of a nut for external threading, a cotter pin for a transverse aperture through the fastener end, and/or other removable fasteners, and combinations thereof. The apparatus may further include angulation adjustment means for adjusting the angulation of the stabilizer guide member, thereby adjusting the size of the aperture sized to accept insertion of the unclaimed fence post. The size of the opening of the post-accepting aperture (69), on the guide end of the stabilizer guide member, is largest when the stabilizer guide member is in a horizontal orientation. The size of that opening changes however, as the stabilizer guide member is moved away from that horizontal plane. The perceived diameter of the typical circle or oval, when viewed from directly above or below the opening, decreases as the stabilizer guide member approaches a more vertical orientation. The user may adjust the orientation of the stabilizer guide member to decrease that aperture's vertical opening to the extent desired to hold the post in an essentially vertical orientation for commencing driving. Moreover, when the stabilizer guide member is in a diagonal orientation, the edge of the aperture may be set to touch the post on opposite sides, with one touch-point higher than the other touch-point, thereby providing additional stabilizing guidance. When ready to remove the apparatus, the user can then re-adjust the orientation of the stabilizer guide member to increase the perceived diameter of the aperture, so that the apparatus can be lifted off the partially-driven post for completion of driving. The angulation adjustment means may be selected from the group consisting of: (1) means of varying the connection point where the stabilizer end of the stabilizer guide member pivotably connects to the 3rd support leg, or (2) means for varying the height of the lower connection end of the stabilizer support downstanding from the assembly head, or (3) means for varying the length of the support legs, and combinations thereof. The means of varying the connection point, where the stabilizer end of the stabilizer guide member pivotably connects to the 3rd support leg, may involve the 3rd support leg including a plurality of periodically spaced bore-holes (not shown); and the stabilizer end may include a longitudinal slot or periodically spaced holes (not shown) in cooperating relationship with the bore-holes for receiving a fastening means extending therethrough for firmly connecting the stabilizer end (64) and the 3rd support leg at a location yielding the desired angulation of the stabilizer guide member. The means for varying the height of the lower connection end of the stabilizer support downstanding from the assembly head may involve the stabilizer support including an elongate vertical sleeve (44) fixed between the support plates (41and46), and telescopically accepting a strut (54) affixed therein and downstanding therefrom. Both the sleeve and the strut may further include a plurality of aligned and periodically spaced throughways (not shown) accepting insertion of a fastener therethrough to vary the length of the stabilizer support. The means for varying the length of the support legs may involve each of the support legs defining a hollow lumen telescopically accepting an extender (19,29and39) therein. Both support leg and extender may further include a plurality of aligned and periodically spaced throughways (not shown) accepting insertion of a fastening means after the extender is extending beyond the lumen, to vary the length of the respective support leg. One specific embodiment of the apparatus, expandable from a compact transport configuration to a free-standing use configuration for positioning a fence post essentially vertically to allow the user to manually drive it into the ground, includes a compactable assembly comprising:(a) an assembly head comprising a connecting means for connecting:(1) a pair of essentially parallel front and back support plates (41and46), each support plate including a lower hole (43and48, respectively) aligned with a corresponding lower hole of the other support plate;(2) a pair of pivotable 1st and 2nd support legs, each having a respective 1st and 2nd foot end (18and28) and a respective 1st and 2nd apex end pivotably connected to the assembly head and essentially opposing the apex end of the other support leg, each of the pivotable 1st and 2nd support leg's apex ends defining a cross-sectional area, each apex end of the respective 1st and 2nd support legs may further include a converging tip region (12and22) comprising a terminal tip (14and24), and including:(A) a diagonal planar cutaway (13and23) reducing the cross-sectional area as the tip is approached; and(B) a lower bore (16and26) aligned with the aligned lower holes (43and48) of the front and back support plates, each respective lower bore and lower holes receiving a hinge pin (51and52) enabling the support leg to pivot from a vertical compacted position outwardly to a free-standing use position;(3) a 3rd pivotable support leg having a 3rd foot end (38) and a 3rd apex end pivotably connected36to the assembly head and enabling the apparatus to stand when all three support legs are pivoted outwardly; and(4) a stabilizer support (50) comprising a vertical sleeve (44) fixed between the support plates and telescopically accepting a strut (54) affixed therein and downstanding therefrom, and comprising a lower connection end (57); and(b) a stabilizer guide member (60) comprising:(1) a middle portion pivotably connected to the lower connection end of the stabilizer support;(2) a stabilizer end (64) pivotably connected to the 3rd support leg; and(3) an opposite guide end (68) defining an aperture (69) sized to accept insertion of the unclaimed fence post in a manner positioning it essentially vertically for commencement of the user manually driving it into the ground but facilitating lifting of the apparatus off the partially driven post without altering the vertical positioning thereof. The apparatus may further include angulation adjustment means for adjusting the angulation of the stabilizer guide member. Additionally the pair of essentially parallel support plates may further include an upper hole aligned with a corresponding upper hole of the other support plate. each of the converging tip regions of the respective pivotable 1st and 2nd support legs may further include an upper bore aligned with the upper holes and near the tip, and along a plane closely parallel to the diagonal planar cutaway, each respective upper bore and upper holes receiving a removable fastening pin. When a support leg is in the vertical compacted position, the upper holes of the opposing support plates are aligned with the upper bore near the tip, so that inserting the fastening pin therethrough locks the leg in the compacted position, while inserting the fastening pin through the upper holes in the support plates when the leg is in the free-standing position chocks against the leg to fix the leg in the free-standing position. The angulation adjustment means for adjusting the angulation of the stabilizer guide member comprises means of varying the connection point where the stabilizer end of the stabilizer guide member pivotably connects to the 3rd support leg includes the 3rd support leg having a plurality of periodically spaced bore-holes. The stabilizer end may include a longitudinal slot or periodically spaced holes in cooperating relationship with the bore-holes for receiving a fastening means extending therethrough for firmly connecting the stabilizer end and the 3rd support leg at a location yielding the desired angulation of the stabilizer guide member. Alternatively, the angulation adjustment means for adjusting the angulation of the stabilizer guide member may include means for varying the height of the lower connection end of the stabilizer support downstanding from the assembly head comprising the stabilizer support including an elongate vertical sleeve fixed between the support plates and telescopically accepting a strut affixed therein and downstanding therefrom, both the sleeve and the strut may further include a plurality of aligned and periodically spaced throughways accepting insertion of a fastener therethrough to vary the length of the stabilizer support. Alternatively, the angulation adjustment means for adjusting the angulation of the stabilizer guide member may include means for varying the length of the support legs, including each of the support legs defining a hollow lumen telescopically accepting an extender therein. Both support leg and extender may further include a plurality of aligned and periodically spaced throughways accepting insertion of a fastening means after the extender is extending beyond the lumen, to vary the length of the respective support leg. Although the apparatus may assemble the apparatus in a number of manners or sequences, the following has proven efficient:(1) position each support leg's apex end between the front and back support plates, and align each leg's lower bore with the lower holes of the front and back support plate;(2) thread the hinge pin for each respective support leg through the aligned lower bore and lower holes, and affix a fastener on the leading end of the hinge pin;(3) if you want the apparatus to be in the use configuration, pivot the 1st and 2nd support legs outwardly at each's foot, then insert the fastening pin through the aligned upper holes of the front and back support plates to chock each respective 1st and 2nd support leg in a wide stance; then pivot the 3rd support leg outwardly to stabilize the tri-pod;(4) insert the stabilizer support/strut into the assembly head sleeve to the appropriate amount of downward extension of the lower connection end of the strut, and tighten the compression screw against the strut to affix it into place;(5) thread the pivot pin through the hole in the mid portion of the stabilizer guide member, and then through the bore-hole of the lower connection end of the stabilizer support, and affix a fastener to the leading end; and(6) align a hole in the stabilizer end of the stabilizer guide member, with the bore-hole in the 3rd support leg, then thread a fastening pin through and affix a fastener to the leading end. If you want the apparatus to be in the compacted travel/storage configuration, undo steps (5) and (6) above; and in step 3 above, pivot the 1st and 2nd support legs together, then insert the fastening pin through the upper holes of the front and back support plates aligned with the upper bore, to lock each respective 1st and 2nd support leg in a narrow stance; then pivot the 3rd support leg inwardly. While a preferred embodiment of the present invention has been described, it should be understood that various changes, adaptations and modifications may be made therein without departing from the spirit of the invention. Changes may be made in details, particularly in matters of shape, size, material, and arrangement of parts without exceeding the scope of the invention. While the forms of apparatus herein described constitute preferred embodiments of the invention, it is to be understood that the invention is not limited to these precise forms of apparatus, and that changes may be made therein without departing from the scope and spirit of the invention as defined in the appended claims. Those skilled in the art will recognize improvements and modification to the preferred embodiments of the present disclosure. All such improvements and modifications are considered within the scope of the concepts disclosed herein and the claims that follow. | 19,129 |
11859403 | DETAILED DESCRIPTION The structures disclosed herein for a customizable facility are useful for manufacturing at least one product at a given time. The structures disclosed herein are particularly useful for manufacturing a variety of products that utilize common resources. The present disclosure provides systems and methods that allow for one or more scalable product lines to be at least partially enclosed within a shell of a customizable facility. Because the structure is adaptable, it does not require a user to commit the structure to a single product line for a long period of time. The structure can be reconfigured to meet the dimensional requirements of a product line. The customizable facility of the present disclosure enables a user to decrease construction timelines, reduce capital expenditures, increase global design standardization, and to comply with various standards around the globe. The customizable structure allows for shorter turnaround times from conception to construction, allows for decreased construction site congestion and requires fewer fixed assets when implementing a new product line. Generally, the customizable facility comprises a shell, at least one central unit positioned within the shell, and at least one modular unit, each modular unit being positioned within the shell. FIG.1is a top plan view of an exemplary embodiment of a customizable facility generally indicated at10. The customizable facility ofFIG.1can be constructed in a series of phases, such as a first phase12, a second phase14, and subsequent phases. The features installed in the first phase12of construction of the customizable facility10ofFIG.1include an air controlled entryway16, a changing area18, a utilities area20, a first manufacturing wing22A, a first office space24A, and at least one corridor28allowing occupants of the customizable facility10to move within the customizable facility10from one area to another. Outside of the customizable facility10, there is a yard30that includes a handling area32for handling equipment and materials. The yard area30is shown adjacent to a roadway34. Generally, the customizable facility10can be expanded in any direction. Additionally, the customizable facility10is constructed such that it can expand in a series of construction phases and/or sub-phases within the physical constraints of the surrounding features, such as the yard area30and the roadway34. FIG.1shows additional features that can be added during a second phase14of construction, such as a second manufacturing wing22B and a second office space24B. The layout of the customizable facility10can be configured for manufacturing in clean room settings. The customizable facility10utilizes a hybrid stick or frame build building and modular buildings with a utilities unit (or utility hub). Referring now toFIGS.2A-2E, the relative positions of various components of the customizable facility are shown. FIG.2Ashows a perspective view of the exterior walls of the outer shell36of the customizable facility10. The outer shell (or shell)36at least partially encloses a central unit (which may be a central utilities unit)38and at least partially encloses a plurality of modular units40, as discussed further below. In some embodiments, the outer shell36entirely encloses the utilities unit (which may be a central utilities unit)38and entirely encloses the plurality of modular units40. The outer shell36can be constructed according to traditional stick building or another method, such as, but not limited to, prefabricated modules. For example, the outer shell36can be fabricated from a steel structure using traditional building methods. The outer shell36can be supported on footings secured in the ground. The outer shell36is weatherproof. The outer shell36forms a superstructure. In some embodiments, the outer shell36can be a “Butler” style building, which is known in the art of building construction. The outer shell36includes side walls42that are dimensioned and configured to encircle one or more central units38and one or more modular units40included in the customizable facility10, and described in more detail below. A roof44is secured to upper edges of the side walls42, with the roof44extending over the central unit(s)38and the modular unit(s)40. Thus, the side walls42and the roof44enclose the central unit(s)38and the modular unit(s)40, which are positioned within the shell36. The central unit(s)38and the modular unit(s)40may be supported on a floor of the shell36or on another support surface on which the shell is secured. The customizable facility10provides a partially-modular (what could be called a modular stick build) method that includes a basic superstructure that is then filled in with modular type elements. In one embodiment, the customizable facility10ofFIG.2Ahas an outer height of 30 meters. In one embodiment, each manufacturing wing has a length of 100 meters and a width of 30 meters. FIG.2Bshows the exterior of the customizable facility10in broken lines, with the utilities area in solid lines. The utilities area20can include a central unit (which may be referred to as a Central Utility Bay (CUB) or utilities building or central utility module)38that is positioned towards the middle of the customizable facility10. The shell36ofFIG.1also encloses a future utilities area46, which is fully occupied by a future utilities module inFIG.1. The future utilities area46is adjacent to the utilities module38, and is shown inFIG.1. The future utilities area46can be used as a warehouse area adjacent to the utilities module38. The future utilities area46within this customizable facility10could also suite high bay applications, such as a 40 foot tall warehouse having an automated search and retrieval system (ASARS). In some embodiments, the utilities module38and the future utilities area46are a single utilities module, which is divided into a utilities section and a future utilities section. The central utility module38does not need to be at the center of the customizable facility10. The central utility module38can be positioned along an outer edge of the customizable facility10in some embodiments. FIG.2Cshows the exterior of the customizable facility10in broken lines, with the manufacturing wings22A,22B in solid lines. The manufacturing wings22A,22B are configured to contain modular units40for a product line, such as fermentation modules or purification modules. The customizable facility10is easily expandable and scalable, and the different modular units40within the manufacturing wings22A,22B can be used to produce completely different products in the same customizable facility10. For example, in a modular unit40configured as a first fermentation module, a user could be manufacturing one type of product, such as a monoclonal antibody product derived from a mammalian cell line. In a second modular unit40, the user could manufacture a completely different product, such as a microbial product. The customizable facility10of the present disclosure is capable of supporting multiple product lines simultaneously and multiple customers from a single, expandable superstructure. The customizable facility10of the present disclosure is capable of being expanded to add additional product lines. Reactors can be supported within the modular units40of the manufacturing wings22A,22B of the customizable facility10. The customizable facility10can support any desired and suitable vessel volume. For example, in some aspects such as that shown inFIG.1, the customizable facility10can be configured to contain up to 20,000 liter production vessels, and storage vessels (e.g., harvest) in excess of 20,000 liters (e.g., 23,000-24,000 liters). For example, the customizable facility10can be dimensioned and configured to support vessels having a volume of about 20,000 liters, 15,000 liters, 10,000 liters, 5,000 liters, 2,000 liters and/or 1,000 liters. Vessels having other volumes can also be supported. Any typical manufacturing and clean room equipment can be included in the customizable facility10, and the customizable facility10can be fully suitable for cGMP (current good manufacturing practice) processes. Examples of some equipment that can be fit in the customizable facility10include, but are not limited to: bioreactor, disc stack centrifuge, tangential flow filtration (TFF) skid, depth filtration skid, in-line dilution skid, chromatography columns with associated control equipment, media tank, harvest tank, purification vessels, depth filter holders, water softening and dechlorination system, clean steam generator, water for injection (WFI) storage tank, WFI break tank, WFI still, cooling towers, switchboard, emergency generator, chiller, hydronic pumps, autoclave, air handling units, process waste neutralization (such as a fiberglass reinforced plastic (FRP)), biowaste collection and inactivation system, clean-in-place systems, glass washer, and/or other equipment. Bioreactors in the customizable facility10of the present disclosure can be ground based reactors. Alternatively, the bioreactors could be suspended from the structure itself. For example, the bioreactors could be suspended from one or more of the modular units40. The customizable facility10can include one or more central unit38and one or more modular unit40. In some embodiments, each modular unit40is selected from the group of: a fermentation or cell culture unit, a pre-viral unit, a post-viral unit, a utility yard, a warehouse, a media buffer facility, an office, a personnel unit, a production unit, a fill-finish unit, a dosage formulation unit, and a packaging unit. A production unit is useful for manufacturing a product. A fill-finish unit is useful for filling a container such as a vial. A dosage formulation unit dispenses a set dose of a product. A packaging unit packages a product for distribution or sale. The space allocated for each modular unit can be divided further as needed to fit specific processing requirements. Each manufacturing wing22A,22B can be configured to allow more than one modular unit40to be positioned within the respective manufacturing wing22A,22B. InFIG.1andFIG.2C, a first manufacturing wing22A comprises three modular units40. A second manufacturing wing22B comprises two modular units40. The central utilities area20has a length of 50 meters and a width of 20 meters, and has three internal levels. The central utilities block is expandable. In some embodiments, at least one of the modular units40is a clean room. In some embodiments, at least one of the modular units40includes a clean room section within the respective modular unit40. The building shell36is designed to accommodate different production modules. In some embodiments, the shell can house four 20,000 liter vessels for a mammalian cell line. In some embodiments, the shell can house four 2,000 liter vessels for single-use technology operations. In some embodiments, a manufacturing wing can include a modular unit containing four 20,000 liter vessels and downstream processing equipment and configured for manufacturing a monoclonal antibody product derived from a mammalian cell line, a modular unit containing single-use equipment for manufacturing a monoclonal antibody product derived from a mammalian cell line having four 20,000 liter vessels, a modular unit configured for manufacturing a microbial product, and/or a modular unit containing single-use equipment for manufacturing a microbial product. In one embodiment, a modular unit is configured for mammalian manufacturing and includes four 20,000 liter vessels and downstream processing equipment. In another embodiment, a modular unit includes four 20,000 liter vessels for commercial and clinical production. In another embodiment, a modular unit includes one 1,000 liter vessel for clinical production. In another embodiment, a modular unit is configured for manufacturing a microbial product, and includes one 15,000 liter vessel. In another embodiment, a modular unit includes three 5,000 liter vessels. In another embodiment, a modular unit includes one or more process development labs. In another embodiment, a modular unit includes fill and finish clinical development vial fill equipment, one or more set of lyophilizing equipment, equipment for manufacturing pre-filled syringes, and/or equipment for manufacturing high potency products for commercial applications. In some embodiments, a modular unit includes cell therapy equipment. In some embodiments, a modular unit includes viral therapy equipment. FIG.2Dshows the exterior of the customizable facility10in broken lines, with the first office space24A and the second office space24B in solid lines. The first office space24A includes offices, lockers for personal storage, and a support area. The second office space24B includes offices, lockers for personal storage, and a support area. The front wall48A of the first office space24A forms a portion of the front outer surface of the customizable facility10, as shown inFIG.2A. The front wall48B of the first office space24B forms a portion of the front outer surface of the customizable facility10. Thus, each office space24A,24B is only partially enclosed by the shell36of the customizable facility10. Similarly, in some embodiments, an outer wall of the central unit and/or an outer wall of one of the at least one modular units forms at least a part of the outer wall of the customizable facility. In some embodiments, an upper surface of a central utility module and/or an upper surface of a modular unit forms part of an upper surface of the customizable facility. FIG.2Eshows the exterior of the customizable facility10in broken lines, with the changing area18in solid lines. The changing area18allows users to enter the customizable facility10and change from street clothes into work clothes. The changing area18inFIG.2Eis further subdivided into a male changing area18A and a female changing area18B. In some embodiments, the changing area18is subdivided into two or more changing areas. In some embodiments, the changing area18is not subdivided. In other embodiments, the relative positions of the first manufacturing wing22A and second manufacturing wings22B, the first office space24A, the second office space24B, the changing area18, and the utilities area20can be positioned differently in the customizable facility10and/or oriented differently with respect to the customizable facility10. Scaffolding and corridors28allow users of the customizable facility10to access the utilities unit38of the utilities area20and the modular units (fermentation, etc. modules)40. After adding the second phase14of construction to the customizable facility10, over time a user may wish to further expand the customizable facility10. For example, consumers in the global economy may develop increased demand for a product that the user is manufacturing, or consumers in the global economy may develop increased demand for a product that the user could produce. To respond to such increases in demand for a product, the user can expand the customizable facility10in subsequent phases of construction that add additional features to the customizable facility ofFIG.1. In some embodiments, such additional features (such as additional modular units, an additional manufacturing wing, or another component of a customizable facility) are positioned horizontally adjacent to the first manufacturing wing22A or the second manufacturing wing22B. In some embodiments, such additional features are positioned vertically adjacent to the first manufacturing wing22A and/or the second manufacturing wing22B. Referring now toFIGS.3A-3E, it is possible for a user to expand a manufacturing wing, such as the first manufacturing wing22A or the second manufacturing wing22B ofFIG.1, in different sub-phases. A user could convert a manufacturing wing layout from one of the configurations shown inFIGS.3A-3Eto another configuration shown inFIGS.3A-3E. Alternatively, a user could convert a manufacturing wing layout to another configuration. FIG.3Ashows a partially exploded view of an embodiment of a modular unit40A that is configured as a fill finish module. The fill finish module ofFIG.3Ahas a single floor60A with a footprint of 1,500 square meters. The fill finish module includes a mezzanine for an HVAC plant room and some localized utilities. A free field50A is shown in broken lines adjacent to the fill finish module, and has a footprint of 1,500 square meters. The free field50A can be used for a variety of purposes, such as product storage. Together, the fill finish module40A and the free field50A extend over the 3,000 square meter footprint of the second manufacturing wing22B. FIG.3Bshows a partially exploded view of an embodiment of a modular unit40B that is configured as a “2 k module.” The 2 k module ofFIG.3Bhas a single floor60B with a footprint of 1,500 square meters. The 2 k module can enclose a 2,000 liter vessel. The 2 k module includes a mezzanine for an HVAC plant room and some localized utilities. A free field50B is shown in broken lines adjacent to the 2 k module, and has a footprint of 1,500 square meters. The free field50B can be used for a variety of purposes, such as product storage. Together, the 2 k module40B and the free field50B extend over the 3,000 square meter footprint of the second manufacturing wing22B. FIG.3Cshows a partially exploded view of an embodiment of a modular unit40C that is configured as “a 5 k module.” The 5 k module ofFIG.3Chas a single floor60C with a footprint of 3,000 square meters. The 5 k module can enclose a 5,000 liter vessel. The 5 k module includes a mezzanine for an HVAC plant room and some localized utilities. The 5 k module extends over the 3,000 square meter footprint of the manufacturing wing. FIG.3Dshows a partially exploded view of an embodiment of a modular unit40D that is configured as a “15 k module.” The 15 k module ofFIG.3Dhas a first floor60D and a second floor62. The 15 k module ofFIG.3Dhas a footprint of 3,000 square meters. The 15 k module can enclose a 15,000 liter vessel. The 15 k module includes a local HVAC unit, a clean in place (CIP) unit, and a temperature control unit (TCU). The temperature control unit in some embodiments includes water jackets with heat exchangers on a tank to control the temperature of a tank used in a product line. A CIP unit is typically a modular skid and has several tanks to hold a cleaning solution (such as caustic solutions and bleach), pumps, and sensors to send the cleaning solution to the appropriate tank to be cleaned. The first floor60D of the 15 k module extends over the 3,000 square meter footprint of the manufacturing wing. The second floor62of the 15 k module extends vertically above the first floor of the 15 k module, and extends above the 3,000 square meter footprint of the manufacturing wing. Together, the first floor60D of the 15 k module and the second floor62of the 15 k module have a combined area of 6,000 square meters. FIG.3Eshows a partially exploded view of an embodiment of a modular unit40E that is configured as a “20 k module.” The 20 k module ofFIG.3Ehas a footprint of 3,000 square meters. The 20 k module can enclose a 20,000 liter vessel. The 20 k module includes a local HVAC unit, a CIP unit, and a TCU. The 20 k module includes a first floor, a second floor, and a third floor. The first floor60E of the 20 k module extends over the 3,000 square meter footprint of the manufacturing wing. The second floor64of the 20 k module extends vertically above the first floor60E of the 20 k module, and extends above the 3,000 square meter footprint of the manufacturing wing. The third floor66of the 20 k module extends vertically above the first floor60E of the 20 k module and the second floor64of the 20 k module, and extends above the 3,000 square meter footprint of the manufacturing wing. Together, the first floor60E of the 20 k module, the second floor64of the 20 k module, and the third floor66of the 20 k module have a combined area of 9,000 square meters. FIG.4is a front perspective cutaway view of an exemplary embodiment of a customizable facility generally indicated at110according to the present disclosure. The customizable facility110layout can be configured for manufacturing in clean room settings. The customizable facility110utilizes a hybrid stick or frame build building and modular buildings with a centrally located utility hub (or central unit)114. An outer shell (or shell)112encloses a central unit114and a plurality of modular units116adjacent to the central unit114. The outer shell112can be constructed according to traditional stick building or another method, such as, but not limited to, prefabricated modules. For example, the outer shell112can be fabricated from a steel structure using traditional building methods. The outer shell112can be supported on footings secured in the ground. The outer shell112is weatherproof. The outer shell112forms a superstructure. In some embodiments, the outer shell112can be a “Butler” style building, which is known in the art of building construction. The shell112includes side walls118that are dimensioned and configured to encircle one or more central units114and one or more modular units116included in the customizable facility110, and described in more detail below. A roof120is secured to upper edges of the side walls118, with the roof120extending over the central unit(s)114and the modular unit(s)116. Thus, the side walls118and the roof120enclose the central unit(s)114and the modular unit(s)116, which are positioned within the shell112. The central unit(s)114and the modular unit(s)116may be supported on a floor122of the shell112or on another support surface on which the shell112is secured. The customizable facility110provides a partially-modular (what could be called a modular stick build) method that includes a basic superstructure that is then filled in with modular type elements. Within the shell112, the customizable facility110ofFIG.4includes at least one central unit114, which each may be referred to as a Central Utility Bay (CUB). The central unit114provides central utilities inFIG.4. As shown, the CUB114is in the middle of the structure with modular units116, which may be referred to as manufacturing pods, which stem from the CUB114(or from a plurality of CUBs). InFIG.4, the modular units116are fermentation modules. The customizable facility110is easily expandable and scalable, and the pod/modular approach (i.e., a hub and spoke type approach) allows the different modules to produce completely different products in the same customizable facility110. For example, in a first fermentation module, such as the fermentation module on the left ofFIG.4, a user could be manufacturing one type of product, such as a monoclonal antibody product derived from a mammalian cell line. In a second module, such as the fermentation module on the right ofFIG.4, the user could manufacture a completely different product, such as a microbial product. The customizable facility110of the present disclosure is capable of supporting multiple product lines simultaneously and multiple customers from a single, expandable superstructure. FIG.4shows reactors124supported within the customizable facility110. The customizable facility110can support any desired and suitable vessel volume. For example, in some aspects such as that shown inFIG.4, the facility110can be configured to contain up to 20,000 Liter production vessels, and storage vessels (e.g., harvest) in excess of 20,000 liters (e.g., 23,000-24,000 liters). For example, the customizable facility110can be dimensioned and configured to support vessels124having a volume of about 20,000 liters, 15,000 liters, 10,000 liters, 5,000 liters, 2,000 liters and/or 1,000 liters. Vessels124having other volumes can also be supported. Scaffolding126and corridors128allow users of the facility110to access the central unit (central utility)114and the modular units (fermentation, etc. modules)116. As shown inFIG.4, the scaffolding126is positioned within the shell112. In some embodiments, one or more central units (CUBs)114and the one or more modular units116are arranged in a hub and spoke arrangement. Any typical manufacturing and clean room equipment can be included in the customizable facility110, and the customizable facility110can be fully suitable for cGMP processes. Examples of some equipment that can be fit in the facility110include, but are not limited to: bioreactor, disc stack centrifuge, tangential flow filtration (TFF) skid, depth filtration skid, in-line dilution skid, chromatography columns with associated control equipment, media tank, harvest tank, purification vessels, depth filter holders, water softening and dechlorination system, clean steam generator, water for injection (WFI) storage tank, WFI break tank, WFI still, cooling towers, switchboard, emergency generator, chiller, hydronic pumps, autoclave, air handling units, process waste neutralization (such as a fiberglass reinforced plastic (FRP)), biowaste collection and inactivation system, clean-in-place systems, glass washer, and/or other equipment. Bioreactors in the customizable facility110of the present disclosure can have ground based reactors124as is shown inFIG.4. Alternatively, the bioreactors124could be suspended from the structure itself. For example, the bioreactors124could be suspended from one or more of the modular units116. The shell112ofFIG.4encloses a warehouse area130towards the back right of the facility110. The warehouse area130within this facility110could also suite high bay applications, such as a 40 foot tall warehouse having an automated search and retrieval system (ASARS). The customizable facility110can include one or more central unit114and one or more modular unit116. In some embodiments, each modular unit116is selected from the group of: a fermentation or cell culture unit, a pre-viral unit, a post-viral unit, a utility yard, a warehouse, a media buffer facility, an office, a personnel unit, a production unit, a fill-finish unit, a dosage formulation unit, and a packaging unit. The space allocated for each modular unit can be divided further as needed to fit specific processing requirements. In some embodiments, at least one of the modular unit(s)116is a clean room. FIG.5shows a perspective view of a set of a central unit114and modular units116arranged in an H-shaped layout132. The position of each modular unit116can be adjusted to best fit processing requirements. FIGS.6and7show an embodiment of a customizable facility in which a central unit114and a set of eight modular units, configured as purification units116A and fermentation units116B, are arranged in an H-shaped layout133when viewed from above. The shell112is not shown in these views. The plan view ofFIG.6shows a central unit (labeled as a central utilities building)114having a first row of modular units, configured as purification units116A and fermentation units116B, arranged in a linear array134adjacent to a first side136of the central unit114, and a second row of modular units, configured as purification units116A and fermentation units116B, arranged in a linear array138adjacent to a second side140of the central unit114. The array134of modular units includes four modular units, with a first purification unit116A at a first end of the array134, two fermentation units116B at the middle of the array134, and a second purification unit116A at a second end of the array134. Similarly, the array138of modular units includes four modular units, with a first purification unit116A at a first end of the array138, two fermentation units116B at the middle of the array138, and a second purification unit116A at a second end of the array138. The two fermentation units116B of the first array134of modular units each include a side wall that is in direct facing engagement with a first side wall136of the central unit114. Similarly, the two fermentation units116B of the second array138of modular units each include a side wall that is in direct facing engagement with a second side wall140of the central unit114. The purification units116A are in direct facing relation with their respectively adjacent fermentation units116B. Because of the direct facing engagement of the central unit114and the fermentation units116B, the number of central units114and modular units that can fit within a shell112of a given size is increased. Likewise, the footprint of a shell112required to enclose a given set of central units114and modular units is decreased. Optionally, in some aspects the side walls of the fermentation units116B (or other modular units) need not be in direct facing engagement but could be spaced so as to provide any desired footprint. The modular unit(s)116and the central unit(s)114can be arranged to facilitate manufacture of a plurality of products simultaneously. The modular unit(s)116and central unit(s)114are arranged to efficiently share resources between the manufacturing lines of the respective products. For example, in some embodiments, the central unit114contains at least one of: a power generator, plumbing lines, power lines, and other resources that can be shared by the modular units116. Additionally, the modular unit(s)116and the central unit(s)114can be arranged to facilitate future expansion of manufacturing capacity. For example, a single modular unit116can be utilized initially, with ability to add additional modular units116at a later time with minimal impact to existing operations. In some embodiments, each of the modular units116includes its own respective heating, ventilation, and air conditioning (HVAC) system, as required for operation and segregation. In some embodiments, the hub and spoke arrangement can resemble the letter H, such as in the plan view ofFIG.6. In other embodiments, the hub and spoke arrangement does not resemble the letter H. Other shapes are possible, including but not limited to: a square, a rectangle, a pentagon, and other geometric shapes, so long as it has a central unit (a central utility bay) with at least one modular unit extending from there. Additional shapes are possible, for example, as shown inFIG.10. In some embodiments, for example, a linear “spine” shape can be used or an “E” shape can be used such that the hub and spoke arrangement resembles the letter E. In some embodiments, the central unit114is not at the center of the arrangement of the central unit114and the modular units116. The arrangement of the modular units116and the central unit114is preferably configured to reduce the number of modular units116required for a given set of manufacturing lines. The modular units116can be segmented off from each other to reduce cross-contamination of product or suites. FIG.8shows a plan view of another preferred embodiment of the customizable facility1000of the present disclosure. Two central units114are located towards the bottom center of the plan view of the structure shown inFIG.8, and are positioned between shared corridors128that extend alongside walls of the central units114. To the left of the central units114is a grouping of six modular units. This grouping includes two pre-viral units116C, two post-viral units116D, and two fermentation units116B. To the right of the central units114as shown inFIG.8is a grouping of six modular units, including two pre-viral units116C, two post-viral units116D, and two fermentation units116B. This configuration is designed to expand additional capability as needed (e.g., seeFIG.10as example of an embodiment showing expansion options). Along the top of the facility1000as shown inFIG.8, there are other modular units, including a utility yard unit116E, two warehouse units116F, two media/buffer facility units116G, and office unit116H, and two personnel access units116J. Not shown in this figure is the capability to add independent buffer hold modular units directly above each purification unit. Shared corridors128extend along walls of the units, so that users can access each of the modular units ofFIG.8and the central units114from a common corridor128. The different units can have different classification levels based on grading standards. For example, different units can have different classification levels based on grading standards set by the United States Food and Drug Administration or grading standards set byEudraLex, The Rules Governing Medicinal Products in the European Union Volume4EU Guidelines to Good Manufacturing Practice Medicinal Products for Human and Veterinary Use, supplemented byAnnex1Manufacture of Sterile Medicinal Productsin the European Union. For example, the pre-viral units116C, the post-viral units116D, and the media/buffer facility units116G inFIG.8are classified as “Grade C,” while the fermentation units116B are classified as “Grade D,” according to the European Union standards, and the remaining units are unclassified. Other classifications for the units are possible, and can be selected according to user needs. FIG.9shows another embodiment of a customizable facility1200of the present disclosure.FIG.9includes a central unit (a central utilities building)114having corridors128for clean material and personnel on either side of the central unit114. The corridors128extend from a warehouse116F at an upper end of the facility1200shown inFIG.9and extend beyond the central unit114at the bottom of the facility. On outer sides of the respective corridors128are locker room units116K, pre-viral units116C, post-viral units116D, and fermentation units116B. In an embodiment such as the one shown inFIG.9, the fermentation units116B each have dimensions of 63 feet by 65 feet, and are 35 feet high. In an embodiment such as the one shown inFIG.9, the pre-viral units116C may have dimensions of 62 feet by 50 feet, and are 17 feet high. In an embodiment such as the one shown inFIG.9, the post-viral units116D each have dimensions of 62 feet by 65 feet, and are 35 feet high. In other embodiments, the units may have other dimensions. FIG.10shows another embodiment of a customizable facility1300of the present disclosure, with the shell112not shown.FIG.10includes five rows of zones. A first row (a top row)142in the plan view ofFIG.10includes purification zones117A. A second row144includes fermentation zones117B. A third row150includes a central utilities zone114. A fourth row146includes fermentation zones117B. A fifth row148includes purification zones117A. In some aspects, a customizable facility for manufacturing at least one pharmaceutical product may include at least one central unit and at least one modular unit, but the customizable facility does not include a shell. Each modular unit is in communication with the at least one central unit such that the at least one central unit provides utilities to each modular unit. The zones in solid lines indicate a set of zones that may be provided in an initial configuration. In this initial configuration160, there are three purification zones (PURE 1, PURE 3, PURE 5)117A in the first row142, three fermentation zones (FERM 1, FERM 3, FERM 5)117B in the second row144, a central utilities zone (CENTRAL UTILITIES 1)115in the third row150, three fermentation zones (FERM 2, FERM 4, FERM 6)117B in the fourth row146, and three purification zones (PURE 2, PURE 4, PURE 6)117A in the fifth row148. A set of zones162could be added by extending an array of zones to the right. For example, two additional purification zones (PURE 7, PURE 9)117A could be added to the first row142, two additional fermentation zones (FERM 7, FERM 9)117B could be added to the second row144; additional central utilities zones114could be added to the third row150, two additional fermentation zones (FERM 8, FERM 10)117B could be added to the fourth row146, and two additional purification zones (PURE 8, PURE 10)117A could be added to the fifth row148. Arrows to the right, such as the arrow A between the fermentation zones117B labeled FERM 9 and FERM N+1, indicate the direction of potential expansion of the arrangement of zones. Additional zones could be added to the respective rows as needed, andFIG.10shows a purification unit (PURE N+1)117A at the end of the first row142, a fermentation zone (FERM N+1)117B at the end of the second row144, a fermentation zone (FERM N)117B along the direction of arrow B at the end of the fourth row146, and a purification zone (PURE N)117A at the end of the fifth row148. The value of N can be an integer value selected by a user as needed, and is limited only by the internal dimensions of the shell112within which the modular units116and central unit(s)114are positioned. The third row can be expanded by adding central utilities zones114to the third row150along an arrow C. The zones ofFIG.10are regions in that could each be a central unit or a modular unit (e.g., a fermentation unit, a purification unit, etc.), or regions that could support equipment for a unit. WhereFIG.10shows a zone (such as zone FERM 1), this zone can be subdivided into a fermentation unit FERM 1 and one or more hallways within the zone. In at least some zones, a unit can occupy the entire zone. Modular units116disclosed herein may be further subdivided into sub-units. For example, a unit could have a pre-viral sub-unit and a post-viral sub-unit. The post-viral sub-unit is virus-free. In relation toFIGS.4-9, although the figures show views that are divided into regions that are described as units, the regions of the views can designate zones (such as a purification zone, a fermentation zone, etc.), which each include a unit and one or more hallways for connecting units. FIG.11illustrates another example embodiment of a facility1400in which a central unit114is in the shape of a linear “spine” with a plurality of modules116emanating from the spine. In this embodiment, the modules116can be added subsequently in multiple construction phases such that the facility is expanded over time. According to an aspect of the present disclosure, a method of assembling a facility for manufacturing at least one pharmaceutical product may include providing a shell, positioning at least one central unit at least partially within the shell, and positioning at least one modular unit at least partially within the shell. According to an aspect of the present disclosure, a campus for fabricating at least one pharmaceutical product is provided. One embodiment of a campus1500is shown inFIGS.12and13. The campus1500includes five customizable facilities, each indicated at1510. Each customizable facility1510is configured to manufacture at least one pharmaceutical product. The five customizable facilities1510rely on the existing infrastructure and support network provided by the campus. For example, media can be provided to the customizable facilities1510from a media/buffer plant (media/buffer facility)1520positioned near the customizable facilities1510. InFIG.12, the media/buffer plant1520is adjacent four of the customizable facilities1510. In some aspects, the media/buffer plant1520is operatively coupled and/or configured to provide or supply the at least one customizable facility1510with a processing material, such as but not limited to media or buffer. In some aspects, the media/buffer plant1520may be configured to provide the processing material in a transportable container, such as a bag, and transport the processing material to the customizable facility1510via truck, rail, or other ground transport system on the campus. In some aspects, the campus can include a supply line1530, with the respective supply line1530connecting the media/buffer plant1520to each respective customizable facility1510to supply each customizable facility1510with media for manufacturing the pharmaceutical product(s). In some embodiments, the supply line1530is a connecting corridor that connects the media/buffer plant1520to each customizable facility1510. In some embodiments, the connecting corridor is a covered walkway that is 6 meters high. Employees or automated vehicles can transport a processing material such as buffer or media through the connecting corridor to deliver the processing material to each customizable facility1510. In some aspects, a utility building1540is connected by a utility line1550to the media/buffer plant1520to provide at least one first utility to the media/buffer plant1520via the utility line1550. For example, the utility building1540can provide an air supply and a steam supply to the media/buffer plant1520inFIG.12. The utility building1540can be configured to deliver or otherwise provide utilities to the media/buffer plant1520and/or the customizable facilities1510. The utility building1540is positioned adjacent one of the customizable facilities1510. In some aspects, the utility building1540is optional. In some embodiments, the utility building1540also includes one or more utility lines connected to each customizable facility1510, so that the utility building1540supplies utilities to the media/buffer plant1520and to the each customizable facility1510. In some embodiments, the utility building1540can be used to provide utilities to any of the media/buffer plant1520, the customizable facilities1510, a warehouse1560, and any other buildings on the campus. The media/buffer plant area is distinct from the downstream processing area(s) in the manufacturing wing(s) of each customizable facility1510. While the media/buffer plant and the customizable facilities1510are on the same campus1500, no proximity is required as long as the concentrated solutions can be delivered from the media/buffer plant1520to the downstream processing area(s) within each customizable facility1510without adversely affecting the stability or activity of the solutions. Scheduling, formulation, and delivery of the solutions are performed to prepare the solutions at or just before their intended time of use. This arrangement reduces storage space at the site of the bioreactor, and allows multiple manufacturers to share expenses associated with the media/buffer plant1520. In some embodiments, a first floor of a respective one of the customizable facilities1510includes a utilities area. The warehouse1560is positioned adjacent one of the customizable facilities1510inFIG.12. A user may store materials in the warehouse1560and then transport the materials from the warehouse1560to another building on the campus1500, such as one of the customizable facilities1510on the campus. In some aspects, the warehouse is optional. Each customizable facility1510can be configured to manufacture different pharmaceutical products from the other customizable facilities1510on the campus1500. Moreover, as described herein, each customizable facility1510can be configured to produce a plurality of drug products utilizing modules, wings or suites within the customizable facility. FIG.13shows an enlarged view of a portion of the campus1500, showing one of the customizable facilities1510ofFIG.12in further detail. The customizable facility1510ofFIG.13includes different modules. In particular, the customizable facility1510ofFIG.13includes an office module1570, a gown module1580, a utilities module1590, and two manufacturing wings1600A,1600B. The manufacturing wing1600A can be configured so that it has three manufacturing modules1610, which each may be used by a different manufacturer to manufacture a different pharmaceutical product. Each manufacturing module1610has its own dedicated access within the customizable facility1510, with independent routes from the gown module1580to the respective manufacturing module1610. The manufacturing wing1600B can be configured to have a plurality of manufacturing modules in a manner similar to the manufacturing wing1600A. In some embodiments of the campus1500, the first manufacturing wing1600A of at least one of the customizable facilities1510is pre-built and available for use to manufacture at least one pharmaceutical product. When the first manufacturing wing1600A is being entirely utilized for manufacturing operations, the user can build out the second manufacturing wing1600B to be technology agnostic from the first manufacturing wing1600A, meaning the second manufacturing wing1600B is generally configured for a wide range of manufacturing operations to produce a wide range of manufactured products that can be different than the pharmaceutical product produced by the first manufacturing wing1600A. Because the manufacturing wings1600A,1600B are technology agnostic, the campus1500provides flexible manufacturing options to a user. In some embodiments, the second manufacturing wing1600B can be configured to be built within the respective customizable facility1510before the user requires additional manufacturing space. In this manner, additional manufacturing wings are built up in the five customizable facilities1510on the campus1500. For example, when five manufacturing wings are being used for manufacturing pharmaceutical products, the user builds out a sixth manufacturing wing. By building out an additional manufacturing wing in excess of what is needed for manufacturing space, the user ensures that the customizable facility does not have 100% utilization of the manufacturing wings until all ten manufacturing wings (two manufacturing wings in each of the five customizable facilities1510ofFIG.12) are being used for manufacturing pharmaceutical products. The utilities module1590can also be identified as a central unit, and provides at least one second utility to the modular units of the customizable facility1510, which are the office module1570, the gown module1580, the utilities module1590, and the two manufacturing wings1600A,1600B in the embodiment ofFIG.12. In some embodiments of the campus1500, the utility building1540is connected to each of the customizable facilities1510, and the first utility is the same as the second utility. In such embodiments, the utilities module1590supplements the utilities provided to the modular units of the respective customizable facility1510by the utility building1540. In some embodiments, the first utility is different from the second utility. In some embodiments of the campus1500, each customizable facility1510may be a customizable facility as described above in relation toFIGS.1-11. For example, in some embodiments, the customizable facility1510includes at least one central unit, and at least one modular unit in communication with the at least one central unit such that the at least one central unit provides at least one second utility to the at least one modular unit. In some embodiments, the one or more modular units includes a fermentation unit, a pre-viral unit, a post-viral unit, a utility space, a warehouse, a media/buffer plant, an office, a personnel unit, a production unit, a fill-finish unit, a dosage formulation unit, and/or a packaging unit. Although a shell is not shown inFIGS.12and13, each customizable facility1510includes a shell, similar to the shell in the embodiments of the customizable facility described in relation toFIGS.1-2EorFIG.4, or another embodiment of the customizable facility of the present disclosure. In some embodiments, the one or more central unit(s) are positioned at least partially within the shell, and the one or more modular unit(s) are positioned at least partially within the shell. In some embodiments, the customizable facility includes a plurality of modular units arranged to maximize a number of modular units within the shell while minimizing a footprint of the shell. In some embodiments of the campus1500, an outer wall of at least one of the customizable facilities1510is formed by the shell of that customizable facility1510, and the respective shell entirely encloses the one or more central units and the at least one modular units of that customizable facility1510. In some embodiments of the campus1500, the outer wall of at least one of the customizable facilities1510is formed by the shell of that customizable facility1510and at least one of an outer wall of the one or more central units of that customizable facility1510and an outer wall of the one or more modular units of that customizable facility1510. In some embodiments, the shell includes at least one side wall, the at least one side wall encircling the one or more central units and the one or more modular units. A roof is secured to an upper edge of the at least one side wall, the roof extending over the one or more central units and the one or more modular units. The build-out of manufacturing wings in the customizable facilities on the campus is fast and cost-effective. The campus provides faster production line development timelines. Because at least one manufacturing wing is pre-built and available for use, a manufacturer can reduce time-to-market by 12 months in some embodiments, and by 16 months in some embodiments. In some embodiments, the campus allows a user to decrease time-to-market from four-and-a-half years to two years. In some embodiments, the campus allows a user to decrease time-to-market, for example from three years to two years. Pharmaceutical manufacturers can easily scale-up or scale-down their manufacturing line as needed. The campus reduces financial and operational risks to the manufacturer. The campus allows a manufacturer to more easily deal with uncertainty in demand for a pharmaceutical over time. The campus of the present disclosure allows manufacturers to respond rapidly as their needs evolve. The campus provides the utilities and support technologies in one place, by providing buildings such as the utilities building1540, warehouse1560, and media/buffer plant1520that can be commonly used by each of the customizable facilities1510. The campus includes dedicated facilities with state-of-the-art technology. For example, each manufacturer can benefit from the state-of-the-art media/buffer plant, utilities building, and other facilities on the campus. In some embodiments, more or fewer than five customizable facilities1510may be included on the campus1500. In some aspects, the campus can be iteratively constructed over time such that a first customizable facility is constructed and then, once capacity is reached in the first facility, a second customizable facility is brought online, and so on. According to an aspect of the present disclosure, a method of assembling a campus for manufacturing at least one pharmaceutical product is provided. A customizable facility that is configured to manufacture the at least one pharmaceutical product is provided. The customizable facility is configured as an embodiment of a customizable facility described above in relation toFIGS.1-13. A media/buffer plant is provided, and is useful for producing media/buffer that can be delivered to manufacturing module on the campus. In some aspects, the media/buffer plant is operatively coupled and/or configured to provide or supply the at least one customizable facility with a processing material, such as but not limited to media or buffer. In some aspects, the media/buffer plant may be configured to provide the processing material in a transportable container, such as a bag, and transport the processing material to the customizable facility via truck, rail, or other ground transport system on the campus. In some aspects, the campus can include a supply line, with the respective supply line connecting the media/buffer plant to each respective customizable facility to supply each customizable facility with media for manufacturing the pharmaceutical product(s). A first end of a utility line is connected to a utility building and a second end of the utility line is connected to the media/buffer plant to provide at least one first utility to the media/buffer plant via the utility line. For example, the first utility can be steam and/or an air supply. A warehouse is positioned adjacent the customizable facility, and is useful for providing materials to the customizable facility. The media/buffer plant is positioned adjacent the customizable facility, and the utility building is positioned adjacent the customizable facility. When the first manufacturing wing1600A in one of the customizable facilities is being entirely utilized for manufacturing operations, the method includes building out the second manufacturing wing1600B in the respective customizable facility. FIG.14shows a perspective view of the five customizable facilities1510, the media/buffer plant1520, the utility building1540constructed according to the schematic ofFIG.12. FIG.15shows a customizable facility1710having a first manufacturing wing1800A and a second manufacturing wing1800B. The first manufacturing wing1800A includes a first manufacturing module1810A and a second manufacturing module1810B. The second manufacturing wing1800B includes a third manufacturing module1810C. Each manufacturing module1810A,1810B,1810C is a modular unit within its respective manufacturing wing1800A,1800B. Each manufacturing module1810A,1810B,1810C can be operated, owned, or leased by a different manufacturer. In embodiments in which one of the manufacturing modules1810A,1810B,1810C is leased, the module can be leased from an owner of the respective manufacturing module1810A,1810B,1810C. In some embodiments, the owner of a manufacturing module may be an owner of the campus or an owner of the customizable facility1710. Each manufacturer can use a different gown area. In a certain embodiment, a first manufacturer has its own dedicated access to the first manufacturing module1810A and dedicated access to a first gown area1820A. Only workers associated with the first manufacturer can enter the first gown area1820A. Only workers associated with the first manufacturer can enter the first manufacturing module1810A, which is accessible via a first dedicated access route1880A from the first gown area1820A to the first manufacturing module1810A. With this embodiment, a second manufacturer has its own dedicated access to the second manufacturing module1810B and dedicated access to a second gown area1820B. Only workers associated with the second manufacturer can enter the second gown area1820B. Only workers associated with the second manufacturer can enter the second manufacturing module1810B, which is accessible via a second dedicated access route1880B from the second gown area1820B to the second manufacturing module1810B. Continuing with this embodiment, a third manufacturer has its own dedicated access to the third manufacturing module1810C and dedicated access to a third gown area1820C. Only workers associated with the third manufacturer can enter the third gown area1820C. Only workers associated with the third manufacturer can enter the third manufacturing module1810C, which is accessible via a third dedicated access route1880C from the third gown area1820C to the third manufacturing module1810C. The customizable facility1710includes a utility module1890that provides utilities to the other modules in the customizable facility1710, such as the first manufacturing module1810A, the second manufacturing module1810B, and the third manufacturing module1810C. The customizable facility ofFIG.15can be included on a campus of the present disclosure, such as the campus1500ofFIG.12. Because the customizable facility1710includes manufacturing modules1810A,1810B,1810C that each has a respective dedicated access route1880A,1880B,1880C, the manufacturing modules1810A,1810B,1810C are cordoned off from one another. This prevents cross-contamination of employees of the respective manufacturers. The cordoning off of the three manufacturing modules1810A,1810B,1810C also prevents cross-contamination of products manufactured by the respective manufacturers. For example, this prevents the spread of pathogens from one of the manufacturing modules within the customizable facility1710to another one of the manufacturing modules within the customizable facility1710. The utility module1890provides shared utilities to the three manufacturing modules1810A,1810B,1810C. Similarly, when the customizable facility1710is incorporated into a campus, such as a campus shown inFIG.12orFIG.14, a utility building1540is capable of being connected to the three manufacturing modules1810A,1810B,1810C to deliver utilities to the three manufacturing modules1810A,1810B,1810C. In this way, the customizable facility1710provides shared utilities, while providing a secure, isolated manufacturing environment for a manufacturer within a manufacturing module. According to an aspect of the present disclosure, a method of managing a pharmaceutical facility is provided. The method includes providing a campus for fabricating one or more pharmaceutical products. In some embodiments, the campus can be a campus described herein, such as the campus1500ofFIG.12. For example, in some embodiments, the campus includes at least one customizable facility configured to manufacture one or more pharmaceutical products. In some embodiments, the campus further includes a media/buffer plant. In some embodiments, the campus further includes a bagging unit in the media/buffer plant at which media/buffer is bagged so it can be moved by ground transportation to the customizable facility. In some aspects, the media/buffer plant is operatively coupled and/or configured to provide or supply the at least one customizable facility with a processing material, such as but not limited to media or buffer. In some aspects, the media/buffer plant may be configured to provide the processing material in a transportable container, such as a bag, and transport the processing material to the customizable facility via truck, rail, or other ground transport system on the campus. In some aspects, the campus can include a supply line, with the respective supply line connecting the media/buffer plant to each respective customizable facility to supply each customizable facility with media for manufacturing the pharmaceutical product(s) In some embodiments, the campus further includes a utility building connected by a utility line to the media/buffer plant to provide at least one first utility to the media/buffer plant via the utility line. The method of managing the pharmaceutical facility further includes offering at least a portion of the campus (for example, through a sale, a lease or another contract) to a customer desiring to manufacture a pharmaceutical product. In some embodiments, the portion of the campus that is offered to a customer includes a manufacturing wing in one of the customizable facilities on the campus. In some embodiments, the portion of the campus that is offered to a customer includes a manufacturing module within one of the manufacturing wings in one of the customizable facilities on the campus. This method of managing the pharmaceutical facility can be carried out by an owner of the campus. In some embodiments, the owner of the campus offers a customer a first option to buy a portion of the campus and a second option to lease a portion of the campus from the owner. In some embodiments, the owner of the campus only offers a customer an option to buy a portion of the campus. For example, the owner of the campus could offer a customer an option to buy a portion of a customizable facility that is on the campus. In particular, the owner of the campus could offer a customer an option to buy a manufacturing module within the customizable facility. In some embodiments, the owner of the campus only offers a customer an option to lease a portion of the campus. For example, the owner of the campus could offer a customer an option to lease a portion of a customizable facility. In particular, the owner of the campus could offer a customer an option to lease a manufacturing module within the customizable facility. In some embodiments, the owner of the campus could offer a customer another option, such as an option in which the customer rents a portion of the campus for a first period of time and then the customer can choose whether to buy the portion of the campus at the end of the first period of time. Additional ownership and rental options are also within the scope of the present disclosure. In some embodiments, the owner of the campus offers to assign its own employees to manufacture a pharmaceutical product within the offered portion of the campus on behalf of a customer. According to an aspect of the present disclosure, a method of adjusting a capacity of a pharmaceutical facility is provided. The method of adjusting the capacity includes providing a campus for fabricating at least one pharmaceutical product. In some embodiments, the campus can be a campus described herein, such as the campus1500ofFIG.12. For example, in some embodiments, the campus includes at least one customizable facility configured to manufacture one or more pharmaceutical products. In some embodiments, the campus further includes a media/buffer plant. In some embodiments, the campus further includes a bagging unit in the media/buffer plant at which media/buffer is bagged so it can be moved by ground transportation to the customizable facility. In some aspects, the media/buffer plant is operatively coupled and/or configured to provide or supply the at least one customizable facility with a processing material, such as but not limited to media or buffer. In some aspects, the media/buffer plant may be configured to provide the processing material in a transportable container, such as a bag, and transport the processing material to the customizable facility via truck, rail, or other ground transport system on the campus. In some aspects, the campus can include a supply line, with the respective supply line connecting the media/buffer plant to each respective customizable facility to supply each customizable facility with media for manufacturing the pharmaceutical product(s) In some embodiments, the campus further includes a utility building connected by a utility line to the media/buffer plant to provide at least one first utility to the media/buffer plant via the utility line. The method of managing the pharmaceutical facility further includes offering at least a portion of the campus to a customer desiring to manufacture a pharmaceutical product. The method further includes offering at least a first portion of the campus to a first customer desiring to manufacture a first pharmaceutical product. The method further includes constructing at least a second portion of the campus for manufacturing a second pharmaceutical product. The second portion is technology agnostic. For example, the owner of the campus can offer a first manufacturing module to a first customer that desires to manufacture a first pharmaceutical product. The owner of the campus constructs a second manufacturing module (or otherwise ensures that a second manufacturing module is available for use by a second customer). This second manufacturing module is technology agnostic. In some embodiments, the second manufacturing module can be subsequently used by a manufacturer to manufacture a second product, which can be different from the first product or identical to the first product. In some embodiments, the owner of the campus then offers the at least the second portion of the campus to a second customer. The owner of the campus constructs a third manufacturing module (or otherwise ensures that a third manufacturing module is available for use by a third customer). This third manufacturing module is technology agnostic. By building out an additional portion of the campus in excess of what is needed for manufacturing space, the user ensures that the customizable facility does not have 100% utilization of the manufacturing wings until all of the manufacturing wings on the campus are being used for manufacturing pharmaceutical products. In some embodiments, the owner of the campus offers a first customer a first portion of the campus that is accessible only via a first dedicated access route that is accessible by the first customer, but that is not accessible by the second customer. The owner of the campus offers a second customer a second portion of the campus that is accessible only via a second dedicated access route that is accessible by the second customer, but that is not accessible by the first customer. The first portion and the second portion do not need to be limited to manufacturing modules. In some embodiments, the owner of the campus continually maintains a technology agnostic portion of the campus in a ready state for a new customer to begin manufacturing a pharmaceutical. This allows the owner of the campus to quickly respond to changes in demand for a pharmaceutical. The technology agnostic portion of the campus that is in the ready state for the new customer to begin manufacturing a pharmaceutical can be quickly rented, leased, sold, or otherwise used by a new customer or an existing customer to meet market demand for a pharmaceutical. The methods of managing a pharmaceutical facility and of adjusting a capacity of a pharmaceutical facility can be performed by an owner of a campus or another party, such as an operator of a campus or a party acting on behalf of the owner of the campus. Example of a Fermentation Unit The fermentation unit116B houses equipment suitable for cell culture and/or fermentation. For example, equipment for cell culture and fermentation include, but are not limited to, bioreactors (e.g., suitable for culturing cells or fermentation), tanks (e.g., suitable for housing cells, media or products produced by cells), decanting apparatus, centrifuges, pumps, and other equipment useful for product recovery. Refold tanks and microfiltration units would be included for microbial fermentation processes. In one embodiment, the fermentation unit116B contains one or more bioreactor units suitable for culturing cells. A bioreactor unit can perform one or more, or all, of the following: feeding of nutrients and/or carbon sources, injection of suitable gas (e.g., oxygen), flow of fermentation or cell culture medium, separation of gas and liquid phases, maintenance of growth temperature, maintenance of pH level, agitation (e.g., stirring), and/or cleaning/sterilizing. The fermentation unit may contain one, 2, 3, 4, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, or 100, or more bioreactors. In various embodiments, the bioreactor is suitable for batch, semi fed-batch, fed-batch, perfusion, and/or continuous fermentation processes. In one embodiment, the bioreactor is a stirred tank reactor. In one embodiment, the bioreactor is an airlift reactor. In one embodiment, the bioreactor can have a volume between about 100 milliliters and about 50,000 liters. Non-limiting examples include a volume of 100 milliliters, 250 milliliters, 500 milliliters, 750 milliliters, 1 liter, 2 liters, 3 liters, 4 liters, 5 liters, 6 liters, 7 liters, 8 liters, 9 liters, 10 liters, 15 liters, 20 liters, 25 liters, 30 liters, 40 liters, 50 liters, 60 liters, 70 liters, 80 liters, 90 liters, 100 liters, 150 liters, 200 liters, 250 liters, 300 liters, 350 liters, 400 liters, 450 liters, 500 liters, 550 liters, 600 liters, 650 liters, 700 liters, 750 liters, 800 liters, 850 liters, 900 liters, 950 liters, 1000 liters, 1500 liters, 2000 liters, 2500 liters, 3000 liters, 3500 liters, 4000 liters, 4500 liters, 5000 liters, 6000 liters, 7000 liters, 8000 liters, 9000 liters, 10,000 liters, 15,000 liters, 20,000 liters, or 50,000 liters. In one embodiment, the bioreactor is suitable for culturing suspension cells or anchorage-dependent (adherent) cells. In one embodiment, the fermentation suite is suitable for cell therapy and/or viral therapy operations. In one embodiment, the bioreactor is suitable for culturing prokaryotic cells or eukaryotic cells. Examples of cells include, but are not limited to, bacterial cells (e.g.,E. coli. P. pastoris), yeast cells (e.g.,S. cerevisae, T reesei), plant cells, insect cells (e.g., Sf9), Chinese hamster ovary cells (CHO, and any genetically modified or derived CHO cell line), mouse cells (e.g., mouse embryonic fibroblasts, cells derived from mouse cancer models), human cells (e.g., cells from any tissue or organ, cells from a cancer or other diseased cell line, stem cell), hybridoma cells, or other genetically modified or hybrid cells. In one embodiment, the cells express or produce a product, such as a recombinant therapeutic or diagnostic product. Examples of products produced by cells include, but are not limited to, antibody molecules (e.g., monoclonal antibodies, bispecific antibodies), fusion proteins (e.g., Fc fusion proteins, chimeric cytokines), other recombinant proteins (e.g., glycosylated proteins, enzymes, hormones), or lipid-encapsulated particles (e.g., exosomes, virus-like particles). In embodiments, the fermentation unit also contains equipment for separation, purification, and isolation of such products from the cells. In one embodiment, the facility and/or bioreactor can be used for producing biosimilar products. In embodiments, the fermentation unit is in compliance with good manufacturing process and biological safety standards. In one embodiment, the fermentation unit is compliant with biosafety level 1 (BSL1), biosafety level 2 (BSL2), biosafety level 3 (BSL3), or biosafety level 4 (BSL4). The fermentation unit can comprise sub-compartments in which each sub-compartment can be used to perform a different function or aspect that supports the cell culture, fermentation, and production processes. By way of example, the fermentation unit comprises a sub-compartment that houses one or more bioreactors, a sub-compartment that houses equipment for product recovery, a sub-compartment for inoculum, and a sub-compartment for cleaning and decontamination of equipment and the operators handling such equipment. Example of a Down Stream Processing Unit The purification units116A discussed above are examples of downstream processing units. As one example, a standard downstream processing (DSP) unit includes pre-viral separation and post-viral separation sub-units. While viral reduction does occur throughout a typical mammalian cell derived protein purification, the critical viral reduction step is considered to be the appropriate point for spatial segregation with the post-viral separation sub-unit to be considered essentially virus free. The post-viral separation sub-unit houses equipment and utilities suitable for any one of the following: ultrafiltration (tangential filtration), normal filtration, chromatography, formulation, titration, mixing, concentration, buffer exchange, bulk drug substance container filling and freezing. The descriptions of the various embodiments and/or examples of the present disclosure have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein. The descriptions of the various embodiments of the present disclosure can be utilized in the production of pharmaceuticals and biopharmaceutical products. The devices, facilities and methods described herein are suitable for culturing any desired cell line including prokaryotic and/or eukaryotic cell lines. Further, in embodiments, the devices, facilities and methods are suitable for culturing suspension cells or anchorage-dependent (adherent) cells and are suitable for production operations configured for production of pharmaceutical and biopharmaceutical products—such as polypeptide products, nucleic acid products (for example DNA or RNA), or cells and/or viruses such as those used in cellular and/or viral therapies. In embodiments, the cells express or produce a product, such as a recombinant therapeutic or diagnostic product. As described in more detail below, examples of products produced by cells include, but are not limited to, antibody molecules (e.g., monoclonal antibodies, bispecific antibodies), antibody mimetics (polypeptide molecules that bind specifically to antigens but that are not structurally related to antibodies such as e.g. DARPins, affibodies, adnectins, or IgNARs), fusion proteins (e.g., Fc fusion proteins, chimeric cytokines), other recombinant proteins (e.g., glycosylated proteins, enzymes, hormones), viral therapeutics (e.g., anti-cancer oncolytic viruses, viral vectors for gene therapy and viral immunotherapy), cell therapeutics (e.g., pluripotent stem cells, mesenchymal stem cells and adult stem cells), vaccines or lipid-encapsulated particles (e.g., exosomes, virus-like particles), RNA (such as e.g. siRNA) or DNA (such as e.g. plasmid DNA), antibiotics or amino acids. In embodiments, the devices, facilities and methods can be used for producing biosimilars. As mentioned, in embodiments, devices, facilities and methods allow for the production of eukaryotic cells, e.g., mammalian cells or lower eukaryotic cells such as for example yeast cells or filamentous fungi cells, or prokaryotic cells such as Gram-positive or Gram-negative cells and/or products of the eukaryotic or prokaryotic cells, e.g., proteins, peptides, antibiotics, amino acids, nucleic acids (such as DNA or RNA), synthesised by the eukaryotic cells in a large-scale manner. Unless stated otherwise herein, the devices, facilities, and methods can include any desired volume or production capacity including but not limited to bench-scale, pilot-scale, and full production scale capacities. Moreover and unless stated otherwise herein, the devices, facilities, and methods can include any suitable reactor(s) including but not limited to stirred tank, airlift, fiber, microfiber, hollow fiber, ceramic matrix, fluidized bed, fixed bed, and/or spouted bed bioreactors. As used herein, “reactor” can include a fermentor or fermentation unit, or any other reaction vessel and the term “reactor” is used interchangeably with “fermentor.” For example, in some aspects, an example bioreactor unit can perform one or more, or all, of the following: feeding of nutrients and/or carbon sources, injection of suitable gas (e.g., oxygen), inlet and outlet flow of fermentation or cell culture medium, separation of gas and liquid phases, maintenance of temperature, maintenance of oxygen and CO2 levels, maintenance of pH level, agitation (e.g., stirring), and/or cleaning/sterilizing. Example reactor units, such as a fermentation unit, may contain multiple reactors within the unit, for example the unit can have 1, 2, 3, 4, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 60, 70, 80, 90, or 100, or more bioreactors in each unit and/or a facility may contain multiple units having a single or multiple reactors within the facility. In various embodiments, the bioreactor can be suitable for batch, semi fed-batch, fed-batch, perfusion, and/or a continuous fermentation processes. Any suitable reactor diameter can be used. In embodiments, the bioreactor can have a volume between about 100 mL and about 50,000 L. Non-limiting examples include a volume of 100 milliliters, 250 milliliters, 500 milliliters, 750 milliliters, 1 liter, 2 liters, 3 liters, 4 liters, 5 liters, 6 liters, 7 liters, 8 liters, 9 liters, 10 liters, 15 liters, 20 liters, 25 liters, 30 liters, 40 liters, 50 liters, 60 liters, 70 liters, 80 liters, 90 liters, 100 liters, 150 liters, 200 liters, 250 liters, 300 liters, 350 liters, 400 liters, 450 liters, 500 liters, 550 liters, 600 liters, 650 liters, 700 liters, 750 liters, 800 liters, 850 liters, 900 liters, 950 liters, 1000 liters, 1500 liters, 2000 liters, 2500 liters, 3000 liters, 3500 liters, 4000 liters, 4500 liters, 5000 liters, 6000 liters, 7000 liters, 8000 liters, 9000 liters, 10,000 liters, 15,000 liters, 20,000 liters, and/or 50,000 liters. Additionally, suitable reactors can be multi-use, single-use, disposable, or non-disposable and can be formed of any suitable material including metal alloys such as stainless steel (e.g., 316L or any other suitable stainless steel) and Inconel, plastics, and/or glass. In embodiments and unless stated otherwise herein, the devices, facilities, and methods described herein can also include any suitable unit operation and/or equipment not otherwise mentioned, such as operations and/or equipment for separation, purification, and isolation of such products. Any suitable facility and environment can be used, such as traditional stick-built facilities, modular, mobile and temporary facilities, or any other suitable construction, facility, and/or layout. For example, in some embodiments modular clean-rooms can be used. Additionally and unless otherwise stated, the devices, systems, and methods described herein can be housed and/or performed in a single location or facility or alternatively be housed and/or performed at separate or multiple locations and/or facilities. By way of non-limiting examples and without limitation, U.S. Publication Nos. 2013/0280797; 2012/0077429; 2009/0305626; and U.S. Pat. Nos. 8,298,054; 7,629,167; and 5,656,491, which are hereby incorporated by reference in their entirety, describe example facilities, equipment, and/or systems that may be suitable. In embodiments, the cells are eukaryotic cells, e.g., mammalian cells. The mammalian cells can be for example human or rodent or bovine cell lines or cell strains. Examples of such cells, cell lines or cell strains are e.g. mouse myeloma (NSO)-cell lines, Chinese hamster ovary (CHO)-cell lines, HT1080, H9, HepG2, MCF7, MDBK Jurkat, NIH3T3, PC12, BHK (baby hamster kidney cell), VERO, SP2/0, YB2/0, Y0, C127, L cell, COS, e.g., COS1 and COST, QC1-3, HEK-293, VERO, PER.C6, HeLA, EB1, EB2, EB3, oncolytic or hybridoma-cell lines. Preferably the mammalian cells are CHO-cell lines. In one embodiment, the cell is a CHO cell. In one embodiment, the cell is a CHO-K1 cell, a CHO-K1 SV cell, a DG44 CHO cell, a DUXB11 CHO cell, a CHOS, a CHO GS knock-out cell, a CHO FUT8 GS knock-out cell, a CHOZN, or a CHO-derived cell. The CHO GS knock-out cell (e.g., GSKO cell) is, for example, a CHO-K1 SV GS knockout cell. The CHO FUT8 knockout cell is, for example, the Potelligent® CHOK1 SV (Lonza Biologics, Inc.). Eukaryotic cells can also be avian cells, cell lines or cell strains, such as for example, EBx® cells, EB14, EB24, EB26, EB66, or EBv13. In one embodiment, the eukaryotic cells are stem cells. The stem cells can be, for example, pluripotent stem cells, including embryonic stem cells (ESCs), adult stem cells, induced pluripotent stem cells (iPSCs), tissue specific stem cells (e.g., hematopoietic stem cells) and mesenchymal stem cells (MSCs). In one embodiment, the cell is a differentiated form of any of the cells described herein. In one embodiment, the cell is a cell derived from any primary cell in culture. In embodiments, the cell is a hepatocyte such as a human hepatocyte, animal hepatocyte, or a non-parenchymal cell. For example, the cell can be a plateable metabolism qualified human hepatocyte, a plateable induction qualified human hepatocyte, plateable Qualyst Transporter Certified™ human hepatocyte, suspension qualified human hepatocyte (including 10-donor and 20-donor pooled hepatocytes), human hepatic kupffer cells, human hepatic stellate cells, dog hepatocytes (including single and pooled Beagle hepatocytes), mouse hepatocytes (including CD-1 and C57BI/6 hepatocytes), rat hepatocytes (including Sprague-Dawley, Wistar Han, and Wistar hepatocytes), monkey hepatocytes (including Cynomolgus or Rhesus monkey hepatocytes), cat hepatocytes (including Domestic Shorthair hepatocytes), and rabbit hepatocytes (including New Zealand White hepatocytes). Example hepatocytes are commercially available from Triangle Research Labs, LLC, 6 Davis Drive Research Triangle Park, North Carolina, USA 27709. In one embodiment, the eukaryotic cell is a lower eukaryotic cell such as e.g. a yeast cell (e.g.,Pichiagenus (e.g.Pichia pastoris, Pichia methanolica, Pichia kluyveri, andPichia angusta),Komagataellagenus (e.g.Komagataella pastoris, Komagataella pseudopastorisorKomagataellaphaffii),Saccharomycesgenus (e.g.Saccharomyces cerevisae, cerevisiae, Saccharomyces kluyveri, Saccharomyces uvarum),Kluyveromycesgenus (e.g.Kluyveromyces lactis, Kluyveromyces marxianus), theCandidagenus (e.g.Candida utilis, Candida cacaoi, Candida boidinii), theGeotrichumgenus (e.g.Geotrichum fermentans),Hansenula polymorpha, Yarrowia lipolytica, orSchizosaccharomyces pombe. Preferred is the speciesPichia pastoris. Examples forPichia pastorisstrains are X33, GS115, KM71, KM71H; and CBS7435. In one embodiment, the eukaryotic cell is a fungal cell (e.g.Aspergillus(such asA. niger, A. fumigatus, A. orzyae, A. nidula),Acremonium(such asA. thermophilum),Chaetomium(such asC. thermophilum),Chrysosporium(such as C. thermophile),Cordyceps(such asC. militaris),Corynascus, Ctenomyces, Fusarium(such asF. oxysporum),Glomerella(such asG. graminicola),Hypocrea(such asH. jecorina),Magnaporthe(such asM. orzyae),Myceliophthora(such asM. thermophile),Nectria(such asN. heamatococca),Neurospora(such asN. crassa),Penicillium, Sporotrichum(such asS. thermophile),Thielavia(such asT. terrestris, T. heterothallica),Trichoderma(such asT. reesei), orVerticillium(such asV. dahlia)). In one embodiment, the eukaryotic cell is an insect cell (e.g., Sf9, Mimic™ Sf9, Sf21, High Five™ (BT1-TN-5B1-4), or BT1-Ea88 cells), an algae cell (e.g., of the genusAmphora, Bacillariophyceae, Dunaliella, Chlorella, Chlamydomonas, Cyanophyta(cyanobacteria),Nannochloropsis, Spirulina, orOchromonas), or a plant cell (e.g., cells from monocotyledonous plants (e.g., maize, rice, wheat, orSetaria), or from a dicotyledonous plants (e.g., cassava, potato, soybean, tomato, tobacco, alfalfa,Physcomitrella patensorArabidopsis). In one embodiment, the cell is a bacterial or prokaryotic cell. In embodiments, the prokaryotic cell is a Gram-positive cells such asBacillus, Streptomyces Streptococcus, StaphylococcusorLactobacillus. Bacillusthat can be used is, e.g. theB. subtilis, B. amyloliquefaciens, B. licheniformis, B. natto, orB. megaterium. In embodiments, the cell isB. subtilis, such asB. subtilis3NA andB. subtilis168.Bacillusis obtainable from, e.g., theBacillusGenetic Stock Center, Biological Sciences 556, 484 West 12thAvenue, Columbus OH 43210-1214. In one embodiment, the prokaryotic cell is a Gram-negative cell, such asSalmonellaspp. orEscherichia coli, such as e.g., TG1, TG2, W3110, DH1, DHB4, DH5a, HMS 174, HMS174 (DE3), NM533, C600, HB101, JM109, MC4100, XL1-Blue and Origami, as well as those derived fromE. coliB-strains, such as for example BL-21 or BL21 (DE3), all of which are commercially available. Suitable host cells are commercially available, for example, from culture collections such as the DSMZ (Deutsche Sammlung von Mikroorganismen and Zellkulturen GmbH, Braunschweig, Germany) or the American Type Culture Collection (ATCC). In embodiments, the cultured cells are used to produce proteins e.g., antibodies, e.g., monoclonal antibodies, and/or recombinant proteins, for therapeutic use. In embodiments, the cultured cells produce peptides, amino acids, fatty acids or other useful biochemical intermediates or metabolites. For example, in embodiments, molecules having a molecular weight of about 4000 daltons to greater than about 140,000 daltons can be produced. In embodiments, these molecules can have a range of complexity and can include posttranslational modifications including glycosylation. In embodiments, the protein is, e.g., BOTOX, Myobloc, Neurobloc, Dysport (or other serotypes of botulinum neurotoxins), alglucosidase alpha, daptomycin, YH-16, choriogonadotropin alpha, filgrastim, cetrorelix, interleukin-2, aldesleukin, teceleulin, denileukin diftitox, interferon alpha-n3 (injection), interferon alpha-nl, DL-8234, interferon, Suntory (gamma-la), interferon gamma, thymosin alpha 1, tasonermin, DigiFab, ViperaTAb, EchiTAb, CroFab, nesiritide, abatacept, alefacept, Rebif, eptoterminalfa, teriparatide (osteoporosis), calcitonin injectable (bone disease), calcitonin (nasal, osteoporosis), etanercept, hemoglobin glutamer 250 (bovine), drotrecogin alpha, collagenase, carperitide, recombinant human epidermal growth factor (topical gel, wound healing), DWP401, darbepoetin alpha, epoetin omega, epoetin beta, epoetin alpha, desirudin, lepirudin, bivalirudin, nonacog alpha, Mononine, eptacog alpha (activated), recombinant Factor VIII+VWF, Recombinate, recombinant Factor VIII, Factor VIII (recombinant), Alphnmate, octocog alpha, Factor VIII, palifermin, Indikinase, tenecteplase, alteplase, pamiteplase, reteplase, nateplase, monteplase, follitropin alpha, rFSH, hpFSH, micafungin, pegfilgrastim, lenograstim, nartograstim, sermorelin, glucagon, exenatide, pramlintide, iniglucerase, galsulfase, Leucotropin, molgramostirn, triptorelin acetate, histrelin (subcutaneous implant, Hydron), deslorelin, histrelin, nafarelin, leuprolide sustained release depot (ATRIGEL), leuprolide implant (DUROS), goserelin, Eutropin, KP-102 program, somatropin, mecasermin (growth failure), enlfavirtide, Org-33408, insulin glargine, insulin glulisine, insulin (inhaled), insulin lispro, insulin deternir, insulin (buccal, RapidMist), mecasermin rinfabate, anakinra, celmoleukin, 99 mTc-apcitide injection, myelopid, Betaseron, glatiramer acetate, Gepon, sargramostim, oprelvekin, human leukocyte-derived alpha interferons, Bilive, insulin (recombinant), recombinant human insulin, insulin aspart, mecasenin, Roferon-A, interferon-alpha 2, Alfaferone, interferon alfacon-1, interferon alpha, Avonex' recombinant human luteinizing hormone, dornase alpha, trafermin, ziconotide, taltirelin, diboterminalfa, atosiban, becaplermin, eptifibatide, Zemaira, CTC-111, Shanvac-B, HPV vaccine (quadrivalent), octreotide, lanreotide, ancestirn, agalsidase beta, agalsidase alpha, laronidase, prezatide copper acetate (topical gel), rasburicase, ranibizumab, Actimmune, PEG-Intron, Tricomin, recombinant house dust mite allergy desensitization injection, recombinant human parathyroid hormone (PTH) 1-84 (sc, osteoporosis), epoetin delta, transgenic antithrombin III, Granditropin, Vitrase, recombinant insulin, interferon-alpha (oral lozenge), GEM-21S, vapreotide, idursulfase, omnapatrilat, recombinant serum albumin, certolizumab pegol, glucarpidase, human recombinant Cl esterase inhibitor (angioedema), lanoteplase, recombinant human growth hormone, enfuvirtide (needle-free injection, Biojector 2000), VGV-1, interferon (alpha), lucinactant, aviptadil (inhaled, pulmonary disease), icatibant, ecallantide, omiganan, Aurograb, pexigananacetate, ADI-PEG-20, LDI-200, degarelix, cintredelinbesudotox, Favld, MDX-1379, ISAtx-247, liraglutide, teriparatide (osteoporosis), tifacogin, AA4500, T4N5 liposome lotion, catumaxomab, DWP413, ART-123, Chrysalin, desmoteplase, amediplase, corifollitropinalpha, TH-9507, teduglutide, Diamyd, DWP-412, growth hormone (sustained release injection), recombinant G-CSF, insulin (inhaled, AIR), insulin (inhaled, Technosphere), insulin (inhaled, AERx), RGN-303, DiaPep277, interferon beta (hepatitis C viral infection (HCV)), interferon alpha-n3 (oral), belatacept, transdermal insulin patches, AMG-531, MBP-8298, Xerecept, opebacan, AIDSVAX, GV-1001, LymphoScan, ranpirnase, Lipoxysan, lusupultide, MP52 (beta-tricalciumphosphate carrier, bone regeneration), melanoma vaccine, sipuleucel-T, CTP-37, Insegia, vitespen, human thrombin (frozen, surgical bleeding), thrombin, TransMID, alfimeprase, Puricase, terlipressin (intravenous, hepatorenal syndrome), EUR-1008M, recombinant FGF-I (injectable, vascular disease), BDM-E, rotigaptide, ETC-216, P-113, MBI-594AN, duramycin (inhaled, cystic fibrosis), SCV-07, OPI-45, Endostatin, Angiostatin, ABT-510, Bowman Birk Inhibitor Concentrate, XMP-629, 99 mTc-Hynic-Annexin V, kahalalide F, CTCE-9908, teverelix (extended release), ozarelix, rornidepsin, BAY-504798, interleukin4, PRX-321, Pepscan, iboctadekin, rhlactoferrin, TRU-015, IL-21, ATN-161, cilengitide, Albuferon, Biphasix, IRX-2, omega interferon, PCK-3145, CAP-232, pasireotide, huN901-DMI, ovarian cancer immunotherapeutic vaccine, SB-249553, Oncovax-CL, OncoVax-P, BLP-25, CerVax-16, multi-epitope peptide melanoma vaccine (MART-1, gp100, tyrosinase), nemifitide, rAAT (inhaled), rAAT (dermatological), CGRP (inhaled, asthma), pegsunercept, thymosinbeta4, plitidepsin, GTP-200, ramoplanin, GRASPA, OBI-1, AC-100, salmon calcitonin (oral, eligen), calcitonin (oral, osteoporosis), examorelin, capromorelin, Cardeva, velafermin, 131I-TM-601, KK-220, T-10, ularitide, depelestat, hematide, Chrysalin (topical), rNAPc2, recombinant Factor V111 (PEGylated liposomal), bFGF, PEGylated recombinant staphylokinase variant, V-10153, SonoLysis Prolyse, NeuroVax, CZEN-002, islet cell neogenesis therapy, rGLP-1, BIM-51077, LY-548806, exenatide (controlled release, Medisorb), AVE-0010, GA-GCB, avorelin, ACM-9604, linaclotid eacetate, CETi-1, Hemospan, VAL (injectable), fast-acting insulin (injectable, Viadel), intranasal insulin, insulin (inhaled), insulin (oral, eligen), recombinant methionyl human leptin, pitrakinra subcutancous injection, eczema), pitrakinra (inhaled dry powder, asthma), Multikine, RG-1068, MM-093, NBI-6024, AT-001, PI-0824, Org-39141, Cpn10 (autoimmune diseases/inflammation), talactoferrin (topical), rEV-131 (ophthalmic), rEV-131 (respiratory disease), oral recombinant human insulin (diabetes), RPI-78M, oprelvekin (oral), CYT-99007 CTLA4-Ig, DTY-001, valategrast, interferon alpha-n3 (topical), IRX-3, RDP-58, Tauferon, bile salt stimulated lipase, Merispase, alaline phosphatase, EP-2104R, Melanotan-II, bremelanotide, ATL-104, recombinant human microplasmin, AX-200, SEMAX, ACV-1, Xen-2174, CJC-1008, dynorphin A, SI-6603, LAB GHRH, AER-002, BGC-728, malaria vaccine (virosomes, PeviPRO), ALTU-135, parvovirus B19 vaccine, influenza vaccine (recombinant neuraminidase), malaria/HBV vaccine, anthrax vaccine, Vacc-5q, Vacc-4x, HIV vaccine (oral), HPV vaccine, Tat Toxoid, YSPSL, CHS-13340, PTH(1-34) liposomal cream (Novasome), Ostabolin-C, PTH analog (topical, psoriasis), MBRI-93.02, MTB72F vaccine (tuberculosis), MVA-Ag85A vaccine (tuberculosis), FARA04, BA-210, recombinant plague FIV vaccine, AG-702, OxSODrol, rBetV1, Der-p1/Der-p2/Der-p7 allergen-targeting vaccine (dust mite allergy), PR1 peptide antigen (leukemia), mutant ras vaccine, HPV-16 E7 lipopeptide vaccine, labyrinthin vaccine (adenocarcinoma), CIVIL vaccine, WT1-peptide vaccine (cancer), IDD-5, CDX-110, Pentrys, Norelin, CytoFab, P-9808, VT-111, icrocaptide, telbermin (dermatological, diabetic foot ulcer), rupintrivir, reticulose, rGRF, HA, alpha-galactosidase A, ACE-011, ALTU-140, CGX-1160, angiotensin therapeutic vaccine, D-4F, ETC-642, APP-018, rhMBL, SCV-07 (oral, tuberculosis), DRF-7295, ABT-828, ErbB2-specific immunotoxin (anticancer), DT3SSIL-3, TST-10088, PRO-1762, Combotox, cholecystokinin-B/gastrin-receptor binding peptides, 111In-hEGF, AE-37, trasnizumab-DM1, Antagonist G, IL-12 (recombinant), PM-02734, IMP-321, rhIGF-BP3, BLX-883, CUV-1647 (topical), L-19 based radioimmunotherapeutics (cancer), Re-188-P-2045, AMG-386, DC/1540/KLH vaccine (cancer), VX-001, AVE-9633, AC-9301, NY-ESO-1 vaccine (peptides), NA17.A2 peptides, melanoma vaccine (pulsed antigen therapeutic), prostate cancer vaccine, CBP-501, recombinant human lactoferrin (dry eye), FX-06, AP-214, WAP-8294A (injectable), ACP-HIP, SUN-11031, peptide YY [3-36] (obesity, intranasal), FGLL, atacicept, BR3-Fc, BN-003, BA-058, human parathyroid hormone 1-34 (nasal, osteoporosis), F-18-CCR1, AT-1100 (celiac disease/diabetes), JPD-003, PTH(7-34) liposomal cream (Novasome), duramycin (ophthalmic, dry eye), CAB-2, CTCE-0214, GlycoPEGylated erythropoietin, EPO-Fc, CNTO-528, AMG-114, JR-013, Factor XIII, aminocandin, PN-951, 716155, SUN-E7001, TH-0318, BAY-73-7977, teverelix (immediate release), EP-51216, hGH (controlled release, Biosphere), OGP-I, sifuvirtide, TV4710, ALG-889, Org-41259, rhCC10, F-991, thymopentin (pulmonary diseases), r(m)CRP, hepatoselective insulin, subalin, L19-IL-2 fusion protein, elafin, NMK-150, ALTU-139, EN-122004, rhTPO, thrombopoietin receptor agonist (thrombocytopenic disorders), AL-108, AL-208, nerve growth factor antagonists (pain), SLV-317, CGX-1007, INNO-105, oral teriparatide (eligen), GEM-OS1, AC-162352, PRX-302, LFn-p24 fusion vaccine (Therapore), EP-1043, S. pneumoniaepediatric vaccine, malaria vaccine,Neisseria meningitidisGroup B vaccine, neonatal group B streptococcal vaccine, anthrax vaccine, HCV vaccine (gpE1+gpE2+MF-59), otitis media therapy, HCV vaccine (core antigen+ISCOMATRIX), hPTH(1-34) (transdermal, ViaDerm), 768974, SYN-101, PGN-0052, aviscumnine, BIM-23190, tuberculosis vaccine, multi-epitope tyrosinase peptide, cancer vaccine, enkastim, APC-8024, GI-5005, ACC-001, TTS-CD3, vascular-targeted TNF (solid tumors), desmopressin (buccal controlled-release), onercept, and TP-9201. In some embodiments, the polypeptide is adalimumab (HUMIRA), infliximab (REMICADE™), rituximab (RITUXAN™/MAB THERA™) etanercept (ENBREL™) bevacizumab (AVASTIN™), trastuzumab (HERCEPTIN™), pegrilgrastim (NEULASTA™), or any other suitable polypeptide including biosimilars and biobetters. Other suitable polypeptides are those listed below and in Table 1 of US2016/0097074: TABLE 1Protein ProductReference Listed Druginterferon gamma-1bActimmune ®alteplase; tissue plasminogen activatorActivase ®/Cathflo ®Recombinant antihemophilic factorAdvatehuman albuminAlbutein ®LaronidaseAldurazyme ®Interferon alfa-N3, human leukocyteAlferon N ®derivedhuman antihemophilic factorAlphanate ®virus-filtered human coagulation factor IXAlphaNine ® SDAlefacept; recombinant, dimeric fusionAmevive ®protein LFA3-IgBivalirudinAngiomax ®darbepoetin alfaAranesp ™BevacizumabAvastin ™interferon beta-1a; recombinantAvonex ®coagulation factor IXBeneFix ™Interferon beta-1bBetaseron ®TositumomabBEXXAR ®antihemophilic factorBioclate ™human growth hormoneBioTropin ™botulinum toxin type ABOTOX ®AlemtuzumabCampath ®acritumomab; technetium-99 labeledCEA-Scan ®alglucerase; modified form of beta-Ceredase ®glucocerebrosidaseimiglucerase; recombinant form of beta-Cerezyme ®glucocerebrosidasecrotalidae polyvalent immune Fab, ovineCroFab ™digoxin immune fab [ovine]DigiFab ™RasburicaseElitek ®EtanerceptENBREL ®epoietin alfaEpogen ®CetuximabErbitux ™algasidase betaFabrazyme ®UrofollitropinFertinex ™follitropin betaFollistim ™TeriparatideFORTEO ®human somatropinGenoTropin ®GlucagonGlucaGen ®follitropin alfaGonal-F ®antihemophilic factorHelixate ®Antihemophilic Factor; Factor XIIIHEMOFILadefovir dipivoxilHepsera ™TrastuzumabHerceptin ®InsulinHumalog ®antihemophilic factor/von WillebrandHumate-P ®factor complex-humanSomatotropinHumatrope ®AdalimumabHUMIRA ™human insulinHumulin ®recombinant human hyaluronidaseHylenex ™interferon alfacon-1Infergen ®eptifibatideIntegrilin ™alpha-interferonIntron A ®PaliferminKepivanceAnakinraKineret ™antihemophilic factorKogenate ® FSinsulin glargineLantus ®granulocyte macrophage colony-Leukine ®/Leukine ® Liquidstimulating factorlutropin alfa for injectionLuverisOspA lipoproteinLYMErix ™RanibizumabLUCENTIS ®gemtuzumab ozogamicinMylotarg ™GalsulfaseNaglazyme ™NesiritideNatrecor ®PegfilgrastimNeulasta ™OprelvekinNeumega ®FilgrastimNeupogen ®FanolesomabNeutroSpec ™ (formerlyLeuTech ®)somatropin [rDNA]Norditropin ®/NorditropinNordiflex ®MitoxantroneNovantrone ®insulin; zinc suspension;Novolin L ®insulin; isophane suspensionNovolin N ®insulin, regular;Novolin R ®InsulinNovolin ®coagulation factor VIIaNovoSeven ®SomatropinNutropin ®immunoglobulin intravenousOctagam ®PEG-L-asparaginaseOncaspar ®abatacept, fully human soluable fusionOrencia ™proteinmuromomab-CD3Orthoclone OKT3 ®high-molecular weight hyaluronanOrthovisc ®human chorionic gonadotropinOvidrel ®live attenuated Bacillus Calmette-GuerinPacis ®peginterferon alfa-2aPegasys ®pegylated version of interferon alfa-2bPEG-Intron ™Abarelix (injectable suspension);Plenaxis ™gonadotropin-releasing hormoneantagonistepoietin alfaProcrit ®AldesleukinProleukin, IL-2 ®SomatremProtropin ®dornase alfaPulmozyme ®Efalizumab; selective, reversible T-cellRAPTIVA ™blockercombination of ribavirin and alphaRebetron ™interferonInterferon beta 1aRebif ®antihemophilic factorRecombinate ® rAHF/antihemophilic factorReFacto ®LepirudinRefludan ®InfliximabREMICADE ®AbciximabReoPro ™ReteplaseRetavase ™RituximaRituxan ™interferon alfa-2aRoferon-A ®SomatropinSaizen ®synthetic porcine secretinSecreFlo ™BasiliximabSimulect ®EculizumabSOLIRIS (R)PegvisomantSOMAVERT ®Palivizumab; recombinantly produced,Synagis ™humanized mAbthyrotropin alfaThyrogen ®TenecteplaseTNKase ™NatalizumabTYSABRI ®human immune globulin intravenous 5%Venoglobulin-S ®and 10% solutionsinterferon alfa-n1, lymphoblastoidWellferon ®drotrecogin alfaXigris ™Omalizumab; recombinant DNA-derivedXolair ®humanized monoclonalantibody targeting immunoglobulin-EDaclizumabZenapax ®ibritumomab tiuxetanZevalin ™SomatotropinZorbtive ™ (Serostim ®) In embodiments, the polypeptide is a hormone, blood clotting/coagulation factor, cytokine/growth factor, antibody molecule, fusion protein, protein vaccine, or peptide as shown in Table 2. TABLE 2Exemplary ProductsTherapeuticProduct typeProductTrade NameHormoneErythropoietin, Epoein-αEpogen, ProcritDarbepoetin-αAranespGrowth hormone (GH),Genotropin, Humatrope, Norditropin,somatotropinNovIVitropin, Nutropin, Omnitrope,Human follicle-stimulatingProtropin, Siazen, Serostim, Valtropinhormone (FSH)Gonal-F, FollistimHuman chorionicOvidrelgonadotropinLuverisLutropin-αGlcaGenGlucagonGerefGrowth hormone releasingChiRhoStim (human peptide),hormone (GHRH)SecreFlo (porcine peptide)SecretinThyrogenThyroid stimulatinghormone (TSH), thyrotropinBloodFactor VIIaNovo SevenClotting/CoagulationFactor VIIIBioclate, Helixate, Kogenate,FactorsFactor IXRecombinate, ReFactoAntithrombin III (AT-III)BenefixProtein C concentrateThrombate IIICeprotinCytokine/GrowthType I alpha-interferonInfergenfactorInterferon-αn3 (IFNαn3)Alferon NInterferon-β1a (rIFN-β)Avonex, RebifInterferon-β1b (rIFN-β)BetaseronInterferon-γ1b (IFNγ)ActimmuneAldesleukin (interleukinProleukin2(IL2), epidermalKepivancetheymocyte activatingRegranexfactor; ETAFAnril, KineretPalifermin (keratinocytegrowth factor; KGF)Becaplemin (platelet-derived growth factor;PDGF)Anakinra (recombinant IL1antagonist)Antibody moleculesBevacizumab (VEGFAAvastinmAb)ErbituxCetuximab (EGFR mAb)VectibixPanitumumab (EGFR mAb)CampathAlemtuzumab (CD52 mAb)RituxanRituximab (CD20 chimericHerceptinAb)OrenciaTrastuzumab (HER2/NeuHumiramAb)EnbrelAbatacept (CTLA Ab/FcRemicadefusion)AmeviveAdalimumab (TNFα mAb)RaptivaEtanercept (TNFTysabrireceptor/Fc fusion)SolirisInfliximab (TNFα chimericOrthoclone, OKT3mAb)Alefacept (CD2 fusionprotein)Efalizumab (CD11a mAb)Natalizumab (integrin α4subunit mAb)Eculizumab (C5mAb)Muromonab-CD3Other:InsulinHumulin, NovolinFusionHepatitis B surface antigenEngerix, Recombivax HBproteins/Protein(HBsAg)Gardasilvaccines/PeptidesHPV vaccineLYMErixOspARhophylacAnti-Rhesus(Rh)Fuzeonimmunoglobulin GQMONOSEnfuvirtideSpider silk, e.g., fibrion In embodiments, the protein is multispecific protein, e.g., a bispecific antibody as shown in Table 3. TABLE 3Bispecific FormatsName (othernames,ProposedDiseases (orsponsoringBsAbmechanisms ofDevelopmenthealthyorganizations)formatTargetsactionstagesvolunteers)CatumaxomabBsIgG:CD3,Retargeting of TApproved inMalignant ascites(Removab ®,TriomabEpCAMcells to tumor, FcEUin EpCAMFresenius Biotech,mediated effectorpositive tumorsTrion Pharma,functionsNeopharm)ErtumaxomabBsIgG:CD3, HER2Retargeting of TPhase I/IIAdvanced solid(Neovii Biotech,Triomabcells to tumortumorsFresenius Biotech)BlinatumomabBiTECD3, CD19Retargeting of TApproved inPrecursor B-cell(Blincyto ®, AMGcells to tumorUSAALL103, MT 103,Phase II andALLMEDI 538,IIIDLBCLAmgen)Phase IINHLPhase IREGN1979BsAbCD3, CD20(Regeneron)Solitomab (AMGBiTECD3,Retargeting of TPhase ISolid tumors110, MT110,EpCAMcells to tumorAmgen)MEDI 565 (AMGBiTECD3, CEARetargeting of TPhase IGastrointestinal211, MedImmune,cells to tumoradenocancinomaAmgen)RO6958688BsAbCD3, CEA(Roche)BAY2010112BiTECD3, PSMARetargeting of TPhase IProstate cancer(AMG 212, Bayer;cells to tumorAmgen)MGD006DARTCD3, CD123Retargeting of TPhase IAML(Macrogenics)cells to tumorMGD007DARTCD3, gpA33Retargeting of TPhase IColorectal cancer(Macrogenics)cells to tumorMGD011DARTCD19, CD3(Macrogenics)SCORPIONBsAbCD3, CD19Retargeting of T(Emergentcells to tumorBiosolutions,Trubion)AFM11 (AffimedTandAbCD3, CD19Retargeting of TPhase INHL and ALLTherapeutics)cells to tumorAFM12 (AffimedTandAbCD19, CD16Retargeting of NKTherapeutics)cells to tumorcellsAFM13 (AffimedTandAbCD30,Retargeting of NKPhase IIHodgkin'sTherapeutics)CD16Acells to tumorLymphomacellsGD2 (Barbara AnnT cellsCD3, GD2Retargeting of TPhase I/IINeuroblastomaKarmanos Cancerpreloadedcells to tumorandInstitute)with BsAbosteosarcomapGD2 (BarbaraT cellsCD3, Her2Retargeting of TPhase IIMetastatic breastAnn Karmanospreloadedcells to tumorcancerCancer Institute)with BsAbEGFRBi-armedT cellsCD3, EGFRAutologousPhase ILung and otherautologouspreloadedactivated T cellssolid tumorsactivated T cellswith BsAbto EGFR-positive(Roger WilliamstumorMedical Center)Anti-EGFR-armedT cellsCD3, EGFRAutologousPhase IColon andactivated T-cellspreloadedactivated T cellspancreatic(Barbara Annwith BsAbto EGFR-positivecancersKarmanos CancertumorInstitute)rM28 (UniversityTandemCD28,Retargeting of TPhase IIMetastaticHospital Tübingen)scFvMAPGcells to tumormelanomaIMCgp100ImmTACCD3, peptideRetargeting of TPhase I/IIMetastatic(Immunocore)MHCcells to tumormelanomaDT2219ARL2 scFvCD19, CD22Targeting ofPhase IB cell leukemia(NCI, University oflinked toprotein toxin toor lymphomaMinnesota)diphtheriatumortoxinXmAb5871BsAbCD19,(Xencor)CD32bNI-1701BsAbCD47, CD19(NovImmune)MM-111BsAbErbB2,(Merrimack)ErbB3MM-141BsAbIGF-1R,(Merrimack)ErbB3NA (Merus)BsAbHER2,HER3NA (Merus)BsAbCD3,CLEC12ANA (Merus)BsAbEGFR,HER3NA (Merus)BsAbPD1,undisclosedNA (Merus)BsAbCD3,undisclosedDuligotuzumabDAFEGFR,Blockade of 2Phase I and IIHead and neck(MEHD7945A,HER3receptors, ADCCPhase IIcancerGenentech, Roche)Colorectal cancerLY3164530 (EliNotEGFR, METBlockade of 2Phase IAdvanced orLily)disclosedreceptorsmetastatic cancerMM-111HSA bodyHER2,Blockade of 2Phase IIGastric and(MerrimackHER3receptorsPhase IesophagealPharmaceuticals)cancersBreast cancerMM-141,IgG-scFvIGF-1R,Blockade of 2Phase IAdvanced solid(MerrimackHER3receptorstumorsPharmaceuticals)RG7221CrossMabAng2, VEGFABlockade of 2Phase ISolid tumors(RO5520985,proangiogenicsRoche)RG7716 (Roche)CrossMabAng2, VEGFABlockade of 2Phase IWet AMDproangiogenicsOMP-305B83BsAbDLL4/VEGF(OncoMed)TF2Dock andCEA, HSGPretargetingPhase IIColorectal,(Immunomedics)locktumor for PET orbreast and lungradioimagingcancersABT-981DVD-IgIL-1α, IL-1βBlockade of 2Phase IIOsteoarthritis(AbbVie)proinflammatorycytokinesABT-122DVD-IgTNF, IL-17ABlockade of 2Phase IIRheumatoid(AbbVie)proinflammatoryarthritiscytokinesCOVA322IgG-TNF, IL17ABlockade of 2Phase VIIPlaque psoriasisfynomerproinflammatorycytokinesSAR156597TetravalentIL-13, IL-4Blockade of 2Phase IIdiopathic(Sanofi)bispecificproinflammatorypulmonarytandem IgGcytokinesfibrosisGSK2434735Dual-IL-13, IL-4Blockade of 2Phase I(Healthy(GSK)targetingproinflammatoryvolunteers)domaincytokinesOzoralizumabNanobodyTNF, HSABlockade ofPhase IIRheumatoid(ATN103, Ablynx)proinflammatoryarthritiscytokine, binds toHSA to increasehalf-lifeALX-0761 (MerckNanobodyIL-17A/F,Blockade of 2Phase I(HealthySerono, Ablynx)HSAproinflammatoryvolunteers)cytokines, bindsto HSA toincrease half-lifeALX-0061NanobodyIL-6R, HSABlockade ofPhase I/IIRheumatoid(AbbVie, Ablynx;proinflammatoryarthritiscytokine, binds toHSA to increasehalf-lifeALX-0141NanobodyRANKL,Blockade of bonePhase IPostmenopausal(Ablynx,HSAresorption, bindsbone lossEddingpharm)to HSA toincrease half-lifeRG6013/ACE910ART-IgFactor IXa,PlasmaPhase IIHemophilia(Chugai, Roche)factor Xcoagulation Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the disclosure pertains. Although any methods and materials similar or equivalent to those described herein can be used in the practice of and/or for the testing of the present disclosure, the preferred materials and methods are described herein. In describing and claiming the present disclosure, the following terminology will be used according to how it is defined, where a definition is provided. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting. The articles “a” and “an” are used herein to refer to one or to more than one (i.e., to at least one) of the grammatical object of the article. By way of example, “a modular unit” can mean one modular unit or more than one modular unit. Without further description, it is believed that one of ordinary skill in the art can, using the preceding description and illustrative examples, make and utilize the customizable facility of the present disclosure. While this invention has been disclosed with reference to specific aspects, it is apparent that other aspects and variations of this invention may be devised by others skilled in the art without departing from the true spirit and scope of the invention. The appended claims are intended to be construed to include all such aspects and equivalent variations. | 106,217 |
11859404 | DESCRIPTION OF EMBODIMENTS An embodiment of the present disclosure will now be described with reference to the drawing. As shown inFIG.1, a fire resistant shelter1includes a shelter main body (hereinafter referred to as the main body10), a water supply device20, a heat insulating housing30and a drain device50. As shown inFIGS.2(a) and2(b), the main body10is a housing having a bottom plate12, a side wall13, a ceiling14and an underground door11which are made of a concrete plate having a thickness of 30 cm. An inside of the main body10is provided with a floor17, a side heat insulating member15and a ceiling heat insulating member16. The side wall13, the floor17, the side heat insulating member15and the ceiling heat insulating member16jointly define an underground evacuation space110(hereinafter referred to as the evacuation space110). The concrete-made structure includes concrete as a main material, and specifically refers to, for example, an unreinforced concrete structure, reinforced concrete structure, composite structure of a steel plate and concrete. The concrete is a material having a high radiation shielding performance. The concrete has a thickness equal to or larger than a thickness capable of withstanding an assumed load (for example, 30 cm) in the embodiment to have a predetermined radiation shielding performance. A thickness of the main body10is preferably between 0.3 to 0.5 m. A concrete material is preferably ordinary concrete or heavy concrete. When the heavy concrete is used, a higher radiation shielding performance than the ordinary concrete is provided. The evacuation space110refers to a space that is defined inside the main body10and is partially or wholly located in an underground200. Preferably, the entire evacuation space110is located in the underground200. More preferably, the entire main body10is located in the underground200. This reduces an influence of flame heat and suppresses a temperature rise of the evacuation space110. As shown inFIG.3(b), the side wall13includes an underground side wall13bhaving a U-shape in a plan view which are partially or wholly in contact with the underground200and a heat insulating side wall13awhich is connected to each end of the underground side wall13band in contact with a heat insulating space120. An underground door11is attached to the heat insulating side wall13aand an opening13cis formed for the passage between the heat insulating space120and the evacuation space110. As shown inFIG.3(b), the underground door11is an outward-opening door provided on the heat insulating side wall13a, which is open in peacetime and closed in evacuating to the evacuation space110. This enables evacuation into the evacuation space110without opening a heavy door. As shown inFIG.2(a), the underground door11is provided with an annular packing11bon a surface facing an outer periphery of the opening13c. This ensures watertightness, so that water W2can be prevented from entering the evacuation space110when the water W2is stored in the heat insulating space120. Further, a winch11awhich is used for closing the underground door11is arranged in a middle portion of the underground door11on the evacuation space110side. A hook11cis attached to an end of the winch11a. As shown inFIGS.4(a) and4(b), an anchor device60to which the hook11ccan be attached is provided in the vicinity of a heat insulating opening15c. The anchor device60has projecting members60aand60bprojecting toward the evacuation space110, and a bar61. The projecting members60aand60bare arranged opposite with each other across the heat insulating opening15c. One end of the bar61is rotatably fixed to the projecting member60a, and the other end of the bar61is removable from the projecting member60b. A closing process of the underground door11will now be described. As shown inFIG.4(a), the underground door11is in an open state and the bar61is supported by the projecting member60awhile hanging down in peacetime. When a fire breaks out, as shown inFIG.4(b), an evacuee evacuates to the evacuation space110while holding the hook11cin his hand, and rotates the bar61to fix to the projecting member60b. The bar61is fixed to the heat insulating side wall13athrough the projecting members60aand60bin a state of horizontally crossing the heat insulating opening15c. The underground door11is closed by attaching the hook11cto the bar61and winding up the winch11a. The underground door11is partially or wholly located in the underground200. Preferably, the entire underground door11is located in the underground200. This reduces an influence of flame heat and suppresses a temperature rise of the evacuation space110. A floor17is provided at substantially the same height as a lower end of the opening13c. This provides a storage space100abetween the bottom plate12and the floor17. The storage space100ais provided with equipment necessary for evacuation such as emergency supplies and cots, which enables secure and comfortable evacuation. Further, steps between the opening13cand the heat insulating opening15cand the floor17is eliminated. This enables easy evacuation of a person having a disability with his legs to the evacuation space110with a wheelchair. A ceiling heat insulating member16having a thickness of 1.0 m is arranged inside the main body10in a state where the upper end is in contact with the ceiling14and the outer periphery is in contact with the heat insulating side wall13aand the underground side wall13b. The thickness of the ceiling heat insulating member16is preferably 0.8 m to 1.2 m. By providing a heat insulating material that is thicker than a normal thickness, a temperature rise of the evacuation space110due to an influence of flame heat is suppressed. A preferable example of a material of the ceiling heat insulating member16is a fiber-based heat insulating material such as glass wool, cellulose fiber, wool heat insulating material or rock wool, or a foamed plastic heat insulating material such as hard urethane foam, beaded polystyrene foam, or phenol foam. A foamed plastic heat insulating material, which is lightweight and has an excellent resistance to moisture permeation, is more preferable. This reduces the weight and prevents an increase of the weight or a change of the shape due to moisture absorption when left in the highly humid main body10for a long time. Further, a heat insulating member that is made of lightweight cellular concrete may be adopted to abut on the ceiling14as a first layer to form a two-layer structure. This prevents a second layer of the heat insulating member being deformed when the ceiling14becomes hot due to flame heat. A side heat insulating member15having a thickness of 1.0 m is arranged inside the main body10in contact with the heat insulating side wall13a. The side heat insulating member15has a wall heat insulating member15aand an opening heat insulating member15b. The wall heat insulating member15aand the opening heat insulating member15beach have an inclined contact surface whose diameter increases from the outside to the inside on the upper surface portion and the side surface portion. A thickness of the side heat insulating member15is preferably 0.8 m to 1.2 m. The heat insulating material that is thicker than the normal thickness suppresses the temperature rise of the evacuation space110due to the influence of flame heat. The wall heat insulating member15ahas a heat insulating opening15cthat is formed in a region corresponding to the opening13c, and is arranged inside the main body10in contact with the heat insulating side wall13a, the underground side wall13b, and the bottom plate12. This suppresses the temperature rise of the evacuation space110when the internal temperature of the heat insulating space120rises due to the influence of flame heat. The opening heat insulating member15bis provided for inserting into the heat insulating opening15c. The opening heat insulating member15band the heat insulating opening15ccorrespond in shape to each other, and both have a shape that expands from the outside to the inside toward the evacuation space110. This facilitates the insertion of the opening heat insulating member15binto the heat insulating opening15c. Further, the opening heat insulating member15bis attached with a handle15dfor hand gripping. A preferable example of a material of the side heat insulating member15is a fiber-based heat insulating material such as glass wool, cellulose fiber, wool heat insulating material or rock wool, or a foamed plastic heat insulating material such as hard urethane foam, beaded polystyrene foam or phenol foam. A foamed plastic heat insulating material that is lightweight and has an excellent resistance to moisture permeation is more preferable. This reduces the weight and prevents an increase of the weight or a change of the shape due to moisture absorption when left in the highly humid main body10for a long time, As shown inFIG.1, the water supply device20has a ceiling water tank21and an upwardly extending water supply pipe41. Water W1is stored in a recess that is open upward of the ceiling water tank21. The water W1is supplied to the heat insulating space120. As shown inFIG.3(a), the ceiling water tank21has a tank wall23. The tank wall23extends vertically from an end of a tank bottom surface22having a L shape in a plan view including the ceiling14and a horizontal roof34b, and the end of the tank wall23is connected to an inclined roof34a. The tank wall23is made of concrete and preferably has a structural thickness enough to withstand an assumed external force such as seismic force and water pressure. Specifically, the tank wall23does not need to have a thickness to exhibit a predetermined radiation shielding performance. As shown inFIG.2(b), it is preferable that a water amount capacity of the ceiling water tank21is an amount that the water W2is supplied to the heat insulating space120to a height of an upper surface of the underground evacuation space110, plus an amount that evaporates due to the influence of flame heat. That is, the water level of the ceiling water tank21after supplying the water W2to the heat insulating space120preferably corresponds to the water level at which the water W1remains in the ceiling water tank21even after the water W1is evaporated due to the influence of flame heat. The reason will be described below. When a temperature of an outside space150greatly exceeds 100° C. due to the influence of flame heat, the water W1stored in the ceiling water tank21boils and evaporates. The temperature of the ceiling14does not exceed 100° C. due to the latent heat effect of the water W1at that time. This leads to suppression of the temperature of the evacuation space110. As shown inFIG.1, the water supply pipe41has a valve (not shown) that is opened and closed by remote control from the evacuation space110. The water supply pipe41is connected to the ceiling water tank21at one end, extends downward along the surface of the heat insulating side wall13aon the insulation space120side, and is located above the housing deck31cat the other end. The water W1stored in the ceiling water tank21is supplied to the heat insulating space120by remote control from the evacuation space110. The water supply pipe41may be arranged through the evacuation space110, and a manual or automatic valve may be provided in the evacuation space110. The heat insulating housing30has a staircase31(elevating device), a housing side wall33, and a roof34, all of which jointly define the heat insulating space120where water can be stored. The heat insulating space120is connected to the underground door11. The heat insulating side wall13aand the underground door11are connected to the outside space150through the heat insulating space120and are more susceptible to flame heat than the underground side wall13b. The heat insulating housing30is formed to suppress a temperature rise of the heat insulating side wall13aand the underground door11due to the influence of flame heat. The upper end of the staircase31is provided with a landing31ahaving a rectangular shape in a plan view, and a lower end is provided with a stair bottom plate31bhaving a rectangular shape in a plan view and extending horizontally from the bottom plate12of the main body10, and a housing deck31cis arranged on the stair bottom plate31b. The landing31aand the stair bottom plate31bare connected via a slope35having a step31d. The housing deck31cis provided to make the step with the floor17as small as possible. This facilitates the passage of people having disabilities with their legs. A water supply space130is provided between the stair bottom plate31band the housing deck31c. The housing side wall33extends vertically upward from an outer end of the staircase31, and a part of the housing side wall33protrudes into the outside space150. A steel outer door36is provided on the part of the housing side wall33that protrudes into the outside space150. A roof34is connected to an upper end of the housing side wall33, and has a horizontal roof34band an inclined roof34a. The horizontal roof34bextends horizontally from an end of the ceiling14that is connected to the heat insulating side wall13a. The horizontal roof34bcooperates with the ceiling14to form a tank bottom surface22of the ceiling water tank21. The inclined roof34aextends obliquely upwardly from one end of the horizontal roof34b, bends and extends horizontally, and is connected to the housing side wall33that is provided with the outer door36. A vertical distance between the inclined roof34aand the staircase31is preferably set to a height that allows the passage of evacuees without any inconvenience. The heat insulating housing30is made of concrete, and preferably has a structural thickness enough to withstand an assumed external force such as seismic force and water pressure. Specifically, the heat insulating housing30does not need to have a thickness to exhibit a predetermined radiation shielding performance. The drain device50has a drain pump51and a drain pipe52. The drain pump51is adapted to drain the water W2stored in the heat insulating space120and is arranged in the water supply space130. The water supply space130and the heat insulating space120communicate with each other. This allows the water W2to be drained without remaining on the upper surface of the housing deck31c. The drain pipe52is connected to the drain pump51, and is arranged so that its end is located directly above the ceiling water tank21through the underground200and the outside space150. This enables the water W2to be returned to the ceiling water tank21. The following describes a process of evacuation to the fire resistant shelter1. When a fire breaks out, an evacuee releases the closed outer door36, enters the heat insulating space120in the heat insulating housing30from the outside space150, and evacuates to the evacuation space110through the staircase31. The open underground door11is closed according to the process described above. After the closure of the underground door11is confirmed, the valve of the water supply pipe41is released by remote control from the evacuation space110. The water W1stored in the ceiling water tank21is supplied to the heat insulating space120. After being confirmed that the water W2is stored up to a level corresponding to the height of the upper end of the evacuation space110, the valve of the water supply pipe41is closed to stop the supply of the water W1. At that time, the water W1remains in the ceiling water tank21at a predetermined height. The upper surface of the ceiling14is covered with the water W1and is not in direct contact with the flame. Further, a temperature rise of the ceiling14is suppressed due to the latent heat effect when the stored water W1evaporates. The temperature rise of the heat insulating side wall13adue to flame heat is suppressed by the latent heat effect when the water W2stored in the heat insulating space120evaporates, etc., and the temperature rise of the underground side wall13bdue to flame heat is suppressed because the underground side wall13bis buried in the underground200where the influence of flame heat is relatively small. After the extinguishment of the fire is confirmed, the drain pump51is operated from the evacuation space to discharge the water W2to the outside space150and return it to the ceiling water tank21. After confirming the drop of the level of the water W2, the evacuee manually releases the underground door11and escapes to the outside space150. The present disclosure is not limited to the above-described embodiment but various modifications, substitutions, and the like may be made without departing from the technical idea of the present disclosure. For example, in the embodiment, the single ceiling water tank21is provided as the water tank for storing the water W1, but a plurality of water tanks may be provided. The elevating device is the staircase31, but may use a lift that moves along the slope of the staircase31together. This makes it easier for people having disabilities with their legs to go up and down. Further, the staircase31may be replaced with an elevator, or the staircase31and the elevator may be used together. The staircase31extends parallel to a side direction of the heat insulating side wall13ain a plan view, but the extending direction may not be limited to this direction. That is, the staircase31may be arranged without being limited to the direction. The staircase31may also be a spiral staircase. This allows the fire resistant shelter1to be arranged efficiently in site. The ceiling water tank21may be used in various ways. For example, a steel deck may be provided above the ceiling water tank21and the deck may be used as a parking lot. The ceiling water tank21may also be used as a pool and lit up with LED lighting facilities to enjoy the night view. Further, the ceiling water tank21may be used as a Japanese garden-style facility to grow ornamental fish such as Nishikigoi. INDUSTRIAL APPLICABILITY The fire resistant shelter according to the present disclosure can be located in site to enable evacuation in a short period of time. The fire resistant shelter suppresses the temperature rise inside the evacuation space in case of a long-lasting fire, which enables long-term evacuation. The fire resistant shelter can also be used as a nuclear shelter. The industrial applicability is therefore high. REFERENCE SIGNS LIST 1. . . fire resistant shelter10. . . shelter main body11. . . underground door12. . . bottom plate13. . . side wall14. . . ceiling15. . . side heat insulating member16. . . ceiling heat insulating member20. . . water supply device21. . . ceiling water tank30. . . heat insulating housing31. . . staircase (elevating device)41. . . water supply pipe50. . . drain device110. . . underground evacuation space120. . . heat insulating space150. . . outside spaceW1, W2. . . water | 18,976 |
11859405 | DESCRIPTION OF EMBODIMENT(S) Hereinafter, a handle attachment and a lavatory door according to embodiments will be described with reference to the drawings. It should be noted that, in the following description of the embodiments, parts and members having the same functions are denoted by the same reference numerals, and redundant descriptions of parts and members denoted by the same reference numerals are omitted. In the present disclosure, the “handle” is a member that applies a force with a hand or fingers to open or close a door, and is a member that can be provided in a space in which a part of the door is recessed, or provided so as to protrude from the door. The “door hinge” refers to a member that is rotatably attached to the wall surface of an opening portion in which a door is installed. Also, the “door hinge axis” refers to the rotation axis of the door attached by the door hinge. The door hinge axis is substantially parallel to the vertical direction if the rotation axis of the door is vertical, but in cases in which the door is movable in the vertical direction, the door hinge axis may be substantially parallel to the horizontal direction. Further, the “door” of the present disclosure is meant to include a door constructed of a panel including a single plane or a curved surface, a bifold door configured to fold midway along a second door hinge axis, or a door having a bellows-like extendable panel. In addition, the “lock knob” refers to a protruding member (for example, a rod-shaped member) that protrudes from the door toward the room direction in order to lock or unlock the door, and the locking position and the unlocking position can be switched by moving the protruding member. In the present disclosure, one direction parallel to the rotation axis AX of the flap portion25is defined as the first direction DR1, and the direction opposite to the first direction DR1is defined as the second direction DR2. Conventional Example First, with reference toFIG.1, a description will be given of an outline of a conventional door structure.FIG.1illustrates an example of a bifold door1having a center-folding structure for use in a lavatory of an aircraft or the like, as seen from the inside of the lavatory. The bifold door1is rotatably mounted to a wall (not illustrated in the figure) in an aircraft by a door hinge axis2, and is designed so that it can be folded at a center-folding portion4(in other words, a second door hinge axis). When opening the bifold door1from the outside of the lavatory, the door can be opened simply by pushing it with the hand, arm, or elbow. However, in order to open the bifold door1from the inside of the lavatory, it is necessary to pull the handle portion3toward the user with the hand or fingers. In addition, when locking the bifold door1, it is necessary to slide the lock knob5in the lateral direction to reliably protrude the lock portion6to the wall member side of the aircraft. In addition, when unlocking the bifold door1, on the contrary, it is necessary to slide the lock knob5in the lateral direction and reliably pull in the lock portion6from the wall member side of the aircraft. It should be noted that when the lock knob5is operated in the lateral direction, the unlocked state and the locked state are displayed on the outer surface of the lavatory on the display unit7. Accordingly, when entering and leaving the room, it is necessary for the user to operate the handle portion3and the lock knob5by using their fingers and hands. In particular, however, since aircraft lavatories have hand-washing facilities within the lavatory, it is necessary for the user to touch the handle portion3and the lock knob5after washing their hands. As such, from the viewpoint of preventing infectious diseases, it is desirable to make it possible to open and close the door without using fingers or hands. Handle Attachment20According to the First Embodiment FIG.2is a schematic view of a handle attachment. The handle attachment20includes a base portion21and a flap portion25which serves as a first operation portion. The handle attachment20may include an auxiliary base portion26that can be coupled to the base portion21in order to sandwich the door between the base portion21and the auxiliary base portion26. The base portion21is fixed to the wall surface of the door using a fixing member such as a screw. In addition, the flap portion25is rotatably attached to the base portion21via a flap rotation mechanism24such as a pin member. The flap rotation mechanism24is provided on the door wall surface side22of the flap portion25. In addition, the flap portion25has a horizontally long surface that is substantially perpendicular to the door hinge axis on the opposite side23of the door wall surface side. Further, the flap portion25is biased against the base portion21using a member such as a spring so that the end portion27on the far side from the flap rotation mechanism24faces away from the wall surface of the door. Operation of the Handle Attachment20 Next, with reference toFIG.3andFIG.4, the operation when the handle attachment20is installed on the bifold door1will be described. FIG.3illustrates a state in which the bifold door1to which the handle attachment20and the lock knob attachment60are attached is closed. In order to open the door from such a state, as depicted in the figure, an arm or elbow may be hung on the handle attachment20to push the bifold door1in the direction of the arrow in the figure, that is, in the direction of the door hinge axis2. As illustrated inFIG.4, by continuing to push the handle attachment20with an arm or elbow, the door1can be easily opened. In the embodiment illustrated inFIG.3andFIG.4, by attaching the handle attachment20, the door1can be opened and closed without using fingers or hands. More particularly, the opening and closing operation of the door1can be performed with an elbow or an arm. In addition, even in a narrow space such as an aircraft lavatory, the handle attachment20can easily apply the force in the direction of the door hinge axis required for opening and closing the door1with a light force. Accordingly, it is possible to smoothly perform the opening and closing operation. Handle Attachment20Installation Location and Attachment Method It should be noted that, in the example ofFIG.3andFIG.4, although an example is described in which the handle attachment20is installed at the location of a handle portion installed on the door, the installation location of the handle attachment20is not limited to the location where the handle portion is installed. The handle attachment20can also be placed low so as to be operated by a foot. The attachment of the handle attachment20to the door1may be performed using embedded nuts and bolts. Alternatively, more simply, the handle attachment20may be fixed to an existing handle using rivets or adhesives. In addition, the handle attachment20may also be attached to an existing handle without the use of a tool by using a tension rod or a mechanical lock that can be fitted to an existing handle. Handle Attachment Details Next, the handle attachment20will be described with reference to the exploded view illustrated inFIG.5. The base portion21and the flap portion25may be connected to each other by, for example, inserting a pin member50into a pin receiving portion52of the base portion21and a pin receiving portion51of the flap portion25. In this case, the flap rotation mechanism24is constituted by the pin member50. Then, by installing a spring mechanism (not shown in the figure) between the base portion21and the flap portion25, the end portion27is maintained in a suspended state (a leaping state) from the wall surface of the door1. In this way, operations with elbows and arms can be performed more easily. FIG.6is a top view of the handle attachment20, and as shown by the distance a, it can be seen that the end portion27is greatly elevated with respect to the wall surface of the door1indicated by the thick dashed line. FIG.7is a front view seen from the Z direction ofFIG.6, andFIG.8is a side view seen from the X direction ofFIG.6. When the bifold door1is used in a narrow space such as an aircraft lavatory, the clearance between the door and the wall (or the plastic mirror on the wall surface) when the lavatory door is fully opened is usually very small, about 30 mm. Accordingly, when the door1is opened, the handle attachment may come into contact with the wall surface (or the plastic mirror on the wall surface) and damage the contacted object (seeFIG.9AandFIG.9B). Therefore, a spring material is built in the handle attachment20, and normally, the end portion27of the flap portion25is biased to the side where the door opens so as to be in a suspended state (a leaping state) from the door surface. In this state, users can easily recognize the handle attachment20, and easily perform an operation of hanging their arm or elbow on the handle attachment (seeFIG.3) In addition, interference between the door and the wall surface when the door is fully opened is prevented as much as possible by moving the flap portion25of the handle attachment20toward the base portion21against the biasing force of the spring material built in the handle attachment20(seeFIG.9C). By means of such a structure of the handle attachment20, by having the handle attachment20fold when a body hits it in a narrow lavatory, it is also possible to prevent injury when a user interferes with the handle attachment. Further, depending on the type of lavatory, there are cases in which the clearance between the door and the wall (or the plastic mirror on the wall surface) may be 10 mm or less when the door is fully opened. In such cases, it is also possible to prevent interference by embedding the handle attachment20in the thickness direction of the door plate. In addition, the end portion27of the flap portion may have a hook-like structure that curves toward the wall side of the door, as illustrated inFIG.9BandFIG.9C. With such a shape, it is possible to prevent arms or elbows from being inadvertently caught in the door1. It should be noted that, in the above embodiment, an example of applying the handle attachment20to a door that opens and closes in the horizontal direction has been described, but the handle attachment20according to embodiments may be applied to a door of an aircraft baggage storage space that opens and closes in the vertical direction. In addition, the handle attachment20may be applied to a door in a facility such as an aircraft galley. Lock Knob Attachment60According to the First Embodiment FIG.10is a perspective view of a lock knob attachment60, andFIG.11is a side view of the lock knob attachment60. The lock knob attachment60is an attachment that can be attached to the lock knob5. As illustrated inFIG.10andFIG.11, the lock knob attachment60includes an attachment portion61that has a cavity that is capable of engaging with the lock knob5, and a main body portion62that has a larger outer diameter than the attachment portion that protrudes from the attachment portion61in the normal direction of the door surface (seeFIG.11). Operation of the Lock Knob Attachment Next, with reference toFIG.12, an operation when the lock knob attachment60is installed on the bifold door1will be described. FIG.12illustrates a state in which the bifold door1to which the handle attachment20and the lock knob attachment50are attached is closed. In order to unlock or lock the door from such a state, as depicted in the figure, an arm or elbow may be hung on the lock knob attachment60, and the lock knob attachment60may be laterally moved in the direction of the arrow in the figure, that is, a direction away from the door hinge axis2or in a direction that approaches the door hinge axis2. In the lock knob attachment60according to the present embodiment, the diameter of the main body portion62is larger than that of the attachment portion61so that the door of the lavatory can be easily locked by an arm, elbow or the like. In addition, so as not to be mistaken for a door handle and gripped, the tip of the main body portion62has a small diameter and a trapezoidal cross section. However, the shape of the lock knob attachment60is not necessarily limited to such a shape. Second Embodiment Referring toFIG.13toFIG.21, the handle attachment20and the lavatory door1according to the second embodiment will be described.FIG.13is a schematic front view schematically illustrating the lavatory door1according to the second embodiment.FIG.14andFIG.15are schematic perspective views schematically illustrating the handle attachment20according to the second embodiment. It should be noted thatFIG.14is a view corresponding to a state in which the distal end portion27of the flap portion25is farthest from the wall surface of the door, andFIG.15is a view corresponding to a state where the distal end portion27of the flap portion25is closest to the wall surface of the door.FIG.16is a schematic front view schematically illustrating the handle attachment20according to the second embodiment.FIG.17is an exploded perspective view schematically illustrating the handle attachment20according to the second embodiment.FIG.18is a cross-sectional view taken along the line A-A ofFIG.16.FIG.19is a schematic cross-sectional view schematically illustrating the handle attachment20according to the second embodiment.FIG.20andFIG.21are schematic side views schematically illustrating the handle attachment20according to the second embodiment.FIG.20illustrates a state in which the distal end portion27of the flap portion25is farthest from the wall surface is of the door1, andFIG.21illustrates a state in which the distal end portion27of the flap portion25is closest to the wall surface1sof the door1. In the second embodiment, those points that differ from the first embodiment are primarily described, and redundant descriptions of the matters described in the first embodiment will be omitted. Accordingly, even if not explicitly described with respect to the second embodiment, it is needless to say that the matters described with respect to the first embodiment can be adopted in the second embodiment. Lavatory Door1 As illustrated inFIG.13, the lavatory door1is attached to a wall101(more particularly, the wall of the lavatory unit of an aircraft). Door1opens and closes an opening portion OP defined by the wall101. In the example described inFIG.13, the door1includes a door panel10and a handle attachment20that is attached to the door panel10. The door1may include a lock bar6and a lock knob attachment60that is attached to the lock bar6. The door panel10is rotatably attached to the first wall101aof the lavatory100around the door hinge axis AX1. The door panel10may be formed of one panel or a plurality of panels including a first panel11and a second panel12. In the example illustrated inFIG.13, the first panel11and the second panel12are connected so as to be relatively rotatable around the second door hinge axis AX2. In other words, the door1inFIG.13is a bifold door. In the example illustrated inFIG.13, the door panel10(more particularly, the first panel11) has an elongated hole portion13hin which the attachment portion61of the lock knob attachment60can be slidably moved. The main body portion62of the lock knob attachment60is arranged on the front side of the elongated hole portion13h, and the lock bar6is arranged on the back side of the elongated hole portion13h. The lock knob attachment60may be the lock knob attachment according to the first embodiment, or may be a lock knob attachment different from the lock knob attachment according to the first embodiment. In the example described inFIG.13, the door panel10(more particularly, the first panel11) has a second elongated hole portion15hparallel to the elongated hole portion13h. A lock state display portion7is arranged behind the second elongated hole portion15h. The lock state display portion7selectively displays, on the outer surface of the lavatory, a first display indicating that the door1is in the locked state and a second display indicating that the door1is in the unlocked state. Handle Attachment20 The handle attachment20is a portion that is operated by a user when the door1is opened. In the example illustrated inFIG.13, the handle attachment20is attached to the door panel10(more particularly, to the second panel12). In the example illustrated inFIG.14, the handle attachment20includes a base portion21, a flap portion25, a flap rotation mechanism24(more particularly, a pin member50), and a biasing member29. The base portion21is attached to a part of the wall surface is of the door1(in other words, attached to any part of the entire inner wall surface of the door1). In the example illustrated inFIG.13, the base portion21is attached to the door panel10. The flap portion25is pulled by the user to import a pulling force to the door1(more particularly, to the door panel10) via the base portion21. In other words, when the user pulls the flap portion25, the state of the door1is switched from a closed state in which the opening portion OP of the wall101is closed to an open state in which the opening portion OP is open. The flap portion25functions as a first operation unit operated by the user. In the example described inFIG.14, the flap portion25has a base end portion28connected to a flap rotation mechanism24(more particularly, a pin member50) and a distal end portion27arranged at a position separated from the flap rotation mechanism24. The flap portion25preferably has a horizontally elongated shape in which the length in a direction perpendicular to the rotation axis AX of the flap portion25is longer than the length in the direction parallel to the rotation axis AX of the flap portion25. In the example illustrated inFIG.14, the biasing member29biases the flap portion25with respect to the base portion21in a first rotational direction R1around the rotation axis AX. The first rotation direction R1is a direction in which the distal end portion27of the flap portion25separates from the wall surface of the door1. In the example illustrated inFIG.14, the biasing member29is a torsion coil spring29s. In the example illustrated inFIG.14, the pin member50is inserted into the coil portion of the torsion coil spring29s. In addition, one end portion of the torsion coil spring29scomes into contact with the base portion21, and the other end portion of the torsion coil spring29scomes into contact with the flap portion25. From the viewpoint of safety, it is preferable that one end portion and/or the other end portion of the torsion coil spring29sbe accommodated in a groove or a hole. In the example illustrated inFIG.19, one end portion of the torsion coil spring29sis accommodated in a groove21vof the base portion21. In addition, in the example illustrated inFIG.14, the other end portion of the torsion coil spring29sis accommodated in a hole251of the flap portion25. In the example illustrated inFIG.14, the distal end portion27of the flap portion25is biased in a direction away from the wall surface of the door1. In this case, (1) a first effect of making it easy to insert an arm or an elbow between the distal end portion27and the wall surface of the door1, and (2) a second effect of having the distal end portion27retract toward the wall surface side of the door1(seeFIG.15) when the distal end portion27is unintentionally hit by a part of the body or the wall of the lavatory are synergistically achieved. The first effect makes it possible to smoothly open the door1without touching the flap portion25with fingers or hands. In addition, the second effect prevents users from being injured and suppresses damage to the wall or the like. Subsequently, with reference toFIG.1toFIG.21, an optional additional configuration that can be adopted in the second embodiment or the first embodiment described above will be described. Through-Hole Portion25h In the example illustrated inFIG.14, the flap portion25has a through-hole portion25hon which a finger can be hooked. In this case, instead of operating the flap portion25by inserting an arm or elbow between the wall surface of the flap portion25and the door1, it is possible to operate the flap portion25by hooking a finger on the through-hole portion25hof the flap portion25. Accordingly, it is possible to meet both the requests of users who wish to operate the flap portion25using their arm or elbow and the requests of users who wish to operate the flap portion25using their finger. In addition, in the case that the flap portion25is provided with the through-hole portion25h, users can intuitively recognize that the flap portion25is an operation unit to be operated by pulling, rather than an operation unit to be operated by pushing. In the example illustrated inFIG.16, the shape of the through-hole portion25his a non-circular shape (more particularly, a substantially semicircular shape). The through-hole portion25hmay have a substantially linear shape on the side of the flap portion25near the distal end portion27, and a substantial arc shape on the side of the flap portion25near the base end portion28. It should be noted that the shape of the through-hole portion25his not limited to the example illustrated inFIG.16, and the shape of the through-hole portion25hmay be a circular shape. In addition, the through-hole portion25hmay be omitted. Protruding Portion25e In the example illustrated inFIG.16, the distal end portion27of the flap portion25is provided with a protruding portion25ethat protrudes in a direction away from the wall surface of the door1. The protruding portion25eis formed of an elastic material such as rubber (for example, polyurethane or the like). In this case, the protruding portion25efunctions as a buffer portion. When the flap portion25collides with a wall or a mirror or the like, the protruding portion25eof the flap portion25collides with the wall or the mirror. Accordingly, when the protruding portion25eis formed of an elastic material, the risk of damage to the wall, mirror, or flap portion25due to this collision is reduced. In addition, due to the presence of the protruding portion25e, users may hesitate to press the distal end portion27of the flap portion25toward the wall surface of the door1. In other words, the presence of the protruding portion25eallows the user to intuitively recognize that the flap portion25is an operation unit to be operated by pulling, rather than an operation unit to be operated by pushing. Second Operation Portion35 In the example illustrated inFIG.18, the handle attachment20includes a second operation portion35. The second operation portion35is disposed between the wall surface is of the flap portion25and the door1. In the example illustrated inFIG.18, the second operation portion35is fixed to the door1. In this case, the second operation portion35does not rotate about the rotation axis AX. The second operation portion35is pulled by the user to impart a pulling force to the door (more particularly, to the door panel10). In other words, when the user pulls the second operation portion35, the state of the door1is switched from a closed state in which the opening portion OP of the wall101is closed to an open state in which the opening portion OP is open. It is anticipated that there may be cases in which the flap portion25breaks, and use of the flap portion25becomes difficult. Even in this case, the user can easily open the door1by operating the second operation portion35. As such, issues in which users become trapped in the lavatory (more particularly, the lavatory of an aircraft) are prevented. Further, in the example illustrated inFIG.18, the second operation portion35is arranged between the flap portion25and the wall surface is of the door1. Accordingly, users can easily recognize the presence of the second operation portion35that appears when the flap portion25is broken. It should be noted that, in a state before the flap portion25is broken, it is preferable that the second operation portion35is hidden behind the flap portion25. In the example illustrated inFIG.17, a pulling instruction display21dis provided on the surface of the base portion21. In this case, when the flap portion25breaks and the second operation portion35appears, users can easily recognize the operation method (more particularly, a pulling operation) of the second operation portion35. The pulling instruction display21dmay include characters indicating a pulling operation, such as “PULL,” or a symbol indicating a pulling operation. In the example illustrated inFIG.17, the pulling instruction display21dis provided on the surface of the second operation portion25. In the example illustrated inFIG.19, the second operation portion35has a first end portion36and a second end portion37that is farther from the rotation shaft AX compared to the first end portion36. In addition, the second end portion37has an opening portion OP2on which a finger can be hooked. In a case that the second end portion37has the opening portion OP2, the second operation portion35can be operated more easily. In the example illustrated inFIG.19, the opening portion OP2opens in a direction away from the rotation axis AX. Accordingly, the user can insert their finger from the opening portion OP2into the inside of the second operation portion35by moving their finger in a direction toward the rotation axis AX. In the example described inFIG.19, the second operation portion35has a first wall portion38opposing the flap portion25. In addition, when viewed in a direction from the second end portion37toward the first end portion36, the outer surface38tof the first wall portion38has a substantially arc shape protruding toward the flap portion25. In this case, the risk of a finger being strongly pinched between the flap portion25and the second operation portion35is reduced. More particularly, in the example illustrated inFIG.20, the outer surface38tof the first wall portion38has a substantially arc shape in which the distance from the flap portion25increases from the central portion toward the edge portion381ton the first direction DR1side. Accordingly, as illustrated inFIG.21, even when the flap portion25is closest to the second operation portion35, there is a sufficient gap G1between the flap portion25and the edge portion381tto suppress finger pinching. Similarly, in the example illustrated inFIG.21, the outer surface38tof the first wall portion38has a substantially arc in which the distance from the flap portion25increases from the central portion toward the edge portion382ton the second direction DR2side. Accordingly, as illustrated inFIG.21, even when the flap portion25is closest to the second operation portion35, there is a sufficient gap G2between the flap portion25and the edge portion382tto suppress finger pinching. In the example described inFIG.19, when viewed in a direction from the second end portion37toward the first end portion36, the inner surface38nof the first wall portion38has a substantially arc shape protruding toward the flap portion25. In this case, fingers can be easily inserted into the second operation portion35through the opening portion OP2. In addition, since the contact surface (38n) between the inserted fingers and the second operation portion35is arc shaped, the fit of the fingers with the second operation portion35is improved. In the example illustrated inFIG.21, in a state in which the flap portion25is closest to the second operation portion35, the flap portion25is separated from the second operation portion35against the biasing force of the biasing member29. Accordingly, even if the flap portion25rotates and moves toward the second operation portion35due to an impact force applied to the flap portion25, the flap portion25does not collide with the second operation portion35. In this way, damage to the second operation portion35is prevented. In addition, the risk of a finger being strongly pinched between the flap portion25and the second operation portion35is reduced. In the example illustrated inFIG.17, the flap rotation mechanism24includes a pin member50. In addition, in the example illustrated inFIG.17, the base end portion28of the flap portion25includes a first leg portion260having a first through-hole portion260hinto which the pin member50is inserted. Additionally, the base end portion28of the flap portion25may include a second leg portion265having a second through-hole portion265hinto which the pin member50is inserted. In this case, the flap portion25can be stably rotated around the rotation axis AX. It should be noted that the number of leg portions provided on the base end portion28of the flap portion25may be one, two, or three or more. In addition, the width of each leg portion (the length in the direction along the rotation axis AX) is appropriately set in consideration of the required strength and the like. In the example illustrated inFIG.19, within the outer peripheral surface of the first leg portion260, a first exposed surface260a(in other words, a surface not covered by the base portion21) that is externally exposed is formed by a first arc surface centered on the rotation axis AX. Similarly, in the example illustrated inFIG.19, within the outer peripheral surface of the second leg portion265, a second exposed surface265a(in other words, a surface not covered by the base portion21) that is externally exposed is formed by a second arc surface centered on the rotation axis AX. In this case, it is possible to prevent a finger from being pinched between the first leg portion260(or the second leg portion265) and the base portion21when the flap portion25rotates around the rotation shaft AX. In the example illustrated inFIG.18, the first leg portion260includes a first stopper262which can come into contact with the base portion21, and a second stopper263that can come into contact with the base portion21. The first stopper262defines a first rotation limit for when the flap portion25rotates in the first rotation direction R1, and the second stopper263defines a second rotation limit for when the flap portion25rotates in the second rotation direction R2that is opposite to the first rotation direction R1. In the example described inFIG.18, the state in which the first stopper262is in contact with the first contact portion212of the base portion21corresponds to a state in which the distal end portion27of the flap portion25is farthest from the wall surface1sof the door1. In the state in which the distal end portion27of the flap portion25is farthest from the wall surface1sof the door1, the opening angle α of the flap portion25with respect to the wall surface1sof the door1(more particularly, in a cross section perpendicular to the rotation axis AX, the angle formed between the straight line L1that connects the rotation axis AX and the distal end portion27of the flap and the wall surface is of the door1) is preferably greater than or equal to 25 degrees and less than or equal to 45 degrees, or greater than or equal to 30 degrees and less than or equal to 40 degrees, for example. The state in which the second stopper263is in contact with the second contact portion213of the base portion21corresponds to a state in which the distal end portion27of the flap portion25is closest to the wall surface is of the door1. In the state in which the distal end portion27of the flap portion25is closest to the wall surface1sof the door1, the opening angle of the flap portion25with respect to the wall surface is of the door1(more particularly, in a cross section perpendicular to the rotation axis AX, the angle formed between the straight line L1that connects the rotation axis AX and the distal end portion27of the flap and the wall surface is of the door1) is preferably greater than or equal to 1 degree and less than or equal to 8 degrees, greater than or equal to 1 degree and less than or equal to 6 degrees, or greater than or equal to 1 degree and less than or equal to 5 degrees. In the example illustrated inFIG.18, the base portion21and the flap portion25define a non-exposed region SP that cannot be externally accessed regardless of the position of the flap portion25between the first rotation limit and the second rotation limit. In addition, the first stopper262and the second stopper263are arranged in the non-exposed region SP. It should be noted that in the example illustrated inFIG.18, the non-exposed region SP is a closed region surrounded by the base portion21and the first leg portion260. As illustrated inFIG.17, it is preferable that the first stopper262and the second stopper263are not exposed on the inner side surface260nof the first leg portion260(in other words, are hidden by the inner side surface260n). In the case that the first stopper262and the second stopper263are disposed in the non-exposed area SP that cannot be externally accessed, it is possible to prevent fingers from being pinched between the first leg portion260(or the second leg portion265) and the base portion21when the flap portion25rotates around the rotation shaft AX. In the example illustrated inFIG.19, the first leg portion260includes a first arc portion261adisposed on one side of the rotation axis AX and a second arc portion261bdisposed on the other side of the rotation axis AX. In addition, the base portion21includes a third arc portion211athat is always opposed to the first arc portion261aand a fourth arc portion211bthat is always opposed to the second arc portion261b. In the example illustrated inFIG.17, the base portion21includes a first cover portion216and a second cover portion217. The first cover portion216covers the first outer side surface260sof the first leg portion260on the second direction DR2side, and the second cover portion217covers the second outer side surface265sof the second leg portion265on the first direction DR1side. In addition, in the example illustrated inFIG.17, the first opposing surface of the first cover portion216that opposes the first outer side surface260sis formed by the first arc surface216s. In addition, the second opposing surface of the second cover portion217that opposes the second outer side surface265sis formed by the second arc surface217s. The first outer side surface260sof the first leg portion260(or the second outer side surface265sof the second leg portion265) is covered by the first cover portion216(or the second cover portion217), thereby preventing fingers from being pinched between the first leg portion260(or the second leg portion265) and the base portion21when the flap portion25rotates about the rotation axis AX. In the example illustrated inFIG.17, the base portion21includes a base member B and a cover member C. The base member B includes a first support portion B1(in other words, a pin receiving portion52) for rotatably supporting the pin member50and a second support portion B2for rotatably supporting the pin member50(in other words, a pin receiving portion52). It is preferable that the first support portion B1and the second support portion B2are each formed with a through-hole portion into which the pin member50can be inserted. In addition, the first support portion B1and the second support portion B2are preferably made of metal. In this case, even when the first support portion B1and the second support portion B2repeatedly receive loads from the pin member50, the first support portion B1and the second support portion B2are unlikely to be damaged. The entire base member B may be made of metal. In addition, the pin member50may be made of metal. In this case, the pin member50is also unlikely to be damaged. However, in embodiments, it is not excluded that at least one or all of the first support portion B1, the second support portion B2, and the pin member50are made of resin. The cover member C covers the first support portion B1and the second support portion B2. The cover member C may include the above-described second operation portion35. The cover member C may be made of resin, for example. In this case, it is easy to mold the cover member C into a complicated shape. However, in embodiments, it is not excluded that the cover member C is made of metal. In addition, the cover member C may be omitted. For example, the cover member C may be omitted by integrally molding the portion corresponding to the cover member C and the portion corresponding to the base member B. In this case, the entire base portion21may be made of metal or resin. In the example illustrated inFIG.17, end covers C2and C3are arranged at both ends of the cover member C. The end covers C2and C3hide a fastening member (not illustrated inFIG.17) that fixes the base member B to the door panel10so that the user cannot see it. It is preferable that the end covers C2and C3be removable from the main body portion C1of the cover member C. After the pin member50is arranged on the first support portion B1and the second support portion B2, the end covers C2and C3may be attached to the main body portion C1. The present invention is not limited to the above embodiments or modifications, and it is clear that the embodiments or modifications can be appropriately re-configured or modified within the scope of the technical idea of the present invention. In addition, any component used in each embodiment or each modification can be combined with other embodiments or other modifications, and any component can be omitted in each embodiment or modification. It should be noted that the descriptions of numerical values for angles and the like in this specification are merely examples. Accordingly, it is needless to say that the description of the numerical values in the present specification does not limit the scope of claims. This application claims priority to Japanese Patent Application No. 2020-95239, filed Jun. 1, 2020, the disclosure of which is incorporated herein by reference in its entirety. REFERENCE LIST 1. . . Door,1s. . . Wall surface,2. . . Door hinge axis,3. . . Handle portion,4. . . Center-folding portion,5. . . Lock knob,6. . . Lock bar,7. . . Lock state display portion,10. . . Door panel,11. . . First panel,12. . . Second panel,13h. . . Elongated hole portion,15h. . . Second elongated hole portion,20. . . Handle attachment,21. . . Base portion,21d. . . Pulling instruction display,21v. . . Groove,22. . . Door wall surface side,23. . . Opposite side,24. . . Flap rotation mechanism,25. . . Flap portion,25e. . . Protruding portion,25h. . . Through-hole portion,26. . . Auxiliary base portion,27. . . Distal end portion,28. . . Base end portion,29. . . Biasing member,29s. . . Torsion coil spring,35. . . Second operation portion,36. . . First end portion,37. . . Second end portion,38. . . First wall portion,38n. . . Inner surface,38t. . . Outer surface,50. . . Pin member,51. . . Pin receiving portion,52. . . Pin receiving portion,60. . . Lock knob attachment,61. . . Attachment portion,62. . . Main body portion,100. . . Lavatory,101. . . Wall,101a. . . First wall,211a. . . Third arc portion,211b. . . Fourth arc portion,212. . . First contact portion,213. . . Second contact portion,216. . . First cover portion,216s. . . First arc surface,217. . . Second cover portion,217s. . . Second arc surface,251. . . Hole,260. . . First leg portion,260a. . . First exposed surface,260h. . . First through-hole portion,260n. . . Inner side surface,260s. . . Outer side surface,261a. . . First arc portion,261b. . . Second arc portion,262. . . First stopper,263. . . Second stopper,265. . . Second leg portion,265a. . . Second exposed surface,265h. . . Second through-hole portion,265s. . . Outer side surface,381t. . . Edge portion,382t. . . Edge portion, B . . . Base member, B1. . . First support portion, B2. . . Second support portion, C . . . Cover member, C1. . . Main body portion, C2, C3. . . End cover, OP . . . Opening portion, OP2. . . Opening portion | 40,066 |
11859406 | Any of the images are not necessarily to scale. The images are merely schematic representations and are not intended to portray specific parameters of the invention. The images are intended to depict only typical embodiments of the invention, and therefore should not be considered as limiting the scope of the invention. DETAILED DESCRIPTION Referring now to the exhibits,FIG.1shows a known door hardware assembly10including a known strike plate20and spring bolt30. Strike plate20has a strike ramp22on an end24of strike plate20. Strike plate20has a bolt hole26at center of strike plate20. Strike plate20affixes to door jamb12with strike ramp22oriented to receive spring bolt30. Spring bolt30has a bolt ramp32on a side of spring bolt30. Spring bolt30is a portion of the door hardware assembly10. As door14closes, bolt ramp32strikes strike ramp22pushing spring bolt30in and allowing spring bolt30to slide over strike plate20. When door14is aligned with door jamb12the spring bolt30is aligned with bolt hole26on strike plate20and hole in door jamb12. The spring bolt30releases into the bolt hole26and the door14is secured in a closed position. Known strike plates20and spring bolts30are reasonably uniform in terms of mechanism and dimensions. FIGS.2A-2Gshow perspective views of one embodiment of a strike plate covering100. Strike plate covering100may include a sheet of noise dampening material adaptively shaped to cover a strike plate20on a door jamb12(FIG.3). A portion of the strike plate covering100may include a bolt hole insert140. Bolt hole insert140may be adaptively shaped to insert into the bolt hole26of strike plate20. Shape of bolt hole insert140is shown as a trapezoidal projection. Bolt hole insert140may be shaped to adapt to any shape of bolt hole26. Noise dampening material may be sufficiently pliant to allow bolt hole insert140to adapt to various contours of bolt hole26. A portion of the strike plate covering100may include a strike ramp grip150. Strike ramp grip150is located at an end of the strike plate covering100distal to the bolt hole insert140. Strike ramp grip150may be adaptively shaped to grip the strike ramp22of strike plate20. Shape of strike ramp grip150is shown as a curve forming a hooked lip along an end of strike plate covering100. Strike ramp grip150may grip an end of strike ramp22. Noise dampening material may include a 3D-printed flexible resin. The noise dampening material may include a sheet magnet. Noise dampening material may include a rubber or silicone. Noise dampening material may include any material capable of absorbing sound. Noise dampening material may include any material with varying degrees of pliancy. Increased pliancy may allow strike plate covering to adapt to various differences in strike plate shapes and dimensions. The strike plate covering100from a top view may be shaped as a rectangle. Length and width of rectangle may be adaptable to cover strike plate20. The strike plate covering100from a side view may be substantially planar with a trapezoidal projection forming bolt hole insert140. Depth of sheet may be adaptable to allow clearance for closing door14. Strike plate covering100is not limited to specific dimensions. FIGS.3-6show perspectives of one embodiment of strike plate covering100deployed with strike plate20and spring bolt30.FIGS.3and4show orientation of strike plate covering100to strike plate20and spring bolt30.FIGS.5and6show strike plate covering100secured to strike plate22with door14in closed position and spring bolt30released. Strike ramp grip150hooks around end of strike ramp22. Strike plate covering100lies flush with strike plate20. Bolt hole insert140fits into bolt hole26. FIGS.7A-7Hshow perspective views of another embodiment of strike plate covering200. In this embodiment, strike plate covering200includes a first secondary strike pad260. First secondary strike pad260fits over the strike surface202of strike plate covering200including covering strike ramp grip250. First secondary strike pad260may be made of all materials described for strike plate cover100. Material of first secondary strike pad260may be the same or different from the material of strike plate covering200. First secondary strike pad260may provide additional sound absorption to strike plate covering200. First secondary strike pad260may be permanently or temporarily affixed to strike plate covering200. Temporary first secondary strike pads260may be replaced when worn without discarding strike plate covering200. FIGS.8A-8Hshow perspective views of another embodiment of strike plate covering300. In this embodiment, strike plate covering300includes a second secondary strike pad370and a bolt hole insert strike pad380. Second secondary strike pad370fits over the strike surface302of strike plate covering300without covering strike ramp grip350. Bolt hole insert strike pad380fits in a bolt hole strike edge304. As spring bolt30releases into bolt hole insert340a leading edge of spring bolt30strikes the bolt hole strike edge304. Second secondary strike pad370and bolt hole insert strike pad380may be made of all materials described for strike plate cover100. Material of secondary strike pad370and bolt hole insert strike pad380may be the same or different from the material of strike plate covering300. Second secondary strike pad370and bolt hole insert strike pad380may provide additional sound absorption to strike plate covering300. Second secondary strike pad370and bolt hole insert strike pad380may be permanently or temporarily affixed to strike plate covering300. Temporary second secondary strike pads370and bolt hole insert strike pads380may be replaced when worn without discarding strike plate covering300. FIGS.9A-9Hshow perspective views of another embodiment of strike plate covering400. In this embodiment, strike plate covering400includes a set of tension strike ramps490. Tension strike ramps490are affixed to a position492on the strike surface402of strike plate covering400proximate to the bolt hole insert440. The tension strike ramps490extend across the strike surface402towards the strike ramp grip450. With the exception of the attachment positions492, tension strike ramps490are not affixed to the strike plate covering400. Tension strike ramps490are shown as a set of two. Tension strike ramps490may include a single unitary ramp or a plurality of ramps. Tension strike ramps490may provide additional sound absorption to strike plate covering400. FIGS.10A-10Hshow perspective views of another embodiment of strike plate covering500. In this embodiment, strike plate covering500includes a third secondary strike pad560. Third secondary strike pad560fits over the strike surface502of strike plate covering500including covering strike ramp grip550and attaching to a strike ramp leading edge552. With the exception of the attachment position554, third secondary strike pad560is not affixed to the strike plate covering500. Third secondary strike pad560may be made of all materials described for strike plate cover100. Material of third secondary strike pad560may be the same or different from the material of strike plate covering500. Third secondary strike pad560may provide additional sound absorption to strike plate covering500. A sound absorption material556may be inserted between the third secondary strike pad560and the strike surface502. Sound absorption material556may be softer than third secondary strike pad560. Sound absorption material556may include a gel or other super soft material. Sound absorption material556may be made of all materials described for strike plate cover100. Material of sound absorption material556may be the same or different from the material of strike plate covering500. Sound absorption material556may provide additional sound absorption to strike plate covering500. FIG.11shows a flow diagram for one embodiment of a method of deploying a noise reduction strike plate covering100,200,300,400, and500. The method includes placing any of the embodiments of the noise reduction strike plate covering100,200,300,400, and500as described herein over a strike plate without the use of adhesives or hardware. FIGS.5and6show one embodiment of a noise reduction strike plate covering system including a strike plate20; and any of the embodiments of the noise reduction strike plate covering100,200,300,400as described herein over the strike plate22without the use of adhesives or hardware. The foregoing description of various aspects of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously, many modifications and variations are possible. Such modifications and variations that may be apparent to an individual in the art are included within the scope of the invention as defined by the accompanying claims. | 8,896 |
11859407 | DETAILED DESCRIPTION In the following description of the various embodiments, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration, various embodiments of the disclosure that can be practiced. It is to be understood that other embodiments can be utilized. Aspects described herein relate to a secure enclosure for holding an object having buttons, such as a key fob. The secure enclosure allows a user to place a key fob inside a cavity formed by a housing of the enclosure. The secure enclosure also includes a locking mechanism that allows the user to lock and unlock the enclosure so that unauthorized users cannot access the enclosed key fob. An actuator, referred to as a “locking actuator,” may control the locking and unlocking mechanism. The secure enclosure may also include one or more actuators, referred to as “button actuators.” Each button actuator may force or cause a corresponding button of an enclosed key fob into contact (e.g., forced contact) with an underlying region of pins to depress the corresponding button. The secure enclosure may support different configurations of button actuators to accommodate different physical configurations of buttons in the enclosed key fob. The secure enclosure also includes a computing device, which may control the locking actuator and/or one or more button actuators. The computing device may include a wireless communication device, which allows authenticated users to connect and wirelessly operate the actuator(s) in order to lock and unlock the secure enclosure and to activate buttons of a key fob stored inside the secure enclosure via any of a variety of short and/or long range wireless communication protocols as described herein. These and various other arrangements will be described more fully herein. As will be appreciated by one of skill in the art upon reading the following disclosure, various aspects described herein can be embodied as a method, apparatus, a computer system, or a computer program product. Accordingly, various aspects of this disclosure can take the form of an entirely hardware embodiment, an entirely software embodiment, or at least one embodiment combining software and hardware aspects. Furthermore, such aspects can take the form of a computer program product stored by one or more computer-readable storage media having computer-readable program code, or instructions, embodied in or on the storage media. Any suitable computer-readable storage media can be utilized, including hard disks, CD-ROMs, optical storage devices, magnetic storage devices, and/or any combination thereof. In addition, various signals representing data or events as described herein can be transferred between a source and a destination in the form of electromagnetic waves traveling through signal-conducting media such as metal wires, optical fibers, and/or wireless transmission media (e.g., air and/or space). Secure Enclosure Turning now toFIG.1A, a perspective view of a first housing110of a secure enclosure100that is holding or otherwise includes a key fob in accordance with at least one embodiment is shown.FIG.1Aillustrates a top-down perspective view of an open interior of first housing110of secure enclosure100, which may enclose or contain, for example, a key fob124. Obscured elements (i.e., elements covered by other elements) are illustrated in broken lines inFIG.1A. Secure enclosure100may generally be any enclosure that is adapted to enclose an object having buttons (e.g., a key fob, such as key fob124). Secure enclosure100may be made of metal, plastic, or any other material that is sufficiently strong enough to resist tampering. Secure enclosure100also includes a computing device (not shown inFIG.1Afor the purpose of simplicity, and described in greater detail with respect toFIG.2). In some examples, the computing device (e.g., computing device200illustrated inFIG.2) may be attached to first housing110, or second housing150(illustrated inFIG.1C) and may include user input components such as a keypad, touchscreen, or the like. First housing110may include a retaining fence112, pins114, a locking mechanism116, a bottom portion118, and side portions120. First housing110encloses a key fob124. Key fob124includes buttons126A and126B. First housing110may generally be square or rectangular in shape, and may have a bottom portion118that is perpendicular to four side portions120. The interior of bottom portion118and side portions120form a cavity130(illustrated in greater detail with respect toFIG.1D) in which key fob124is secured or contained. Pins114may be attached to bottom portion118and protrude into cavity130formed by bottom portion118and side portions120. Pins114may all be of the same shape or may have differing shapes. Pins114may be arranged in a grid or in any other configuration. Pins114may be arranged in various other configurations as well. A user of secure enclosure100may place a key fob124portion down onto pins114such that the buttons126A and126B of key fob124are in contact or nearly in contact with pins114. To accommodate different positions of key fob buttons, and as discussed in greater detail herein, pins114may be movable to different positions of bottom portion118and/or removable from bottom portion118. As described in greater detail herein, when an actuator located on second housing150(FIG.1C) of secure enclosure100is activated, the actuator presses the region of the key fob124underneath the actuator into the underlying region of pins114, causing a corresponding button of key fob124(e.g., button126A or126B) located underneath the actuator to be depressed. First housing110also includes a retaining fence112, which provides a force (such as friction or another mechanical force) on key fob124to stop key fob124from moving within secure enclosure100, and thereby hold key fob124securely in place. Retaining fence112may include a movable member including a piece of plastic, metal, or any other material that is sufficiently rigid to secure key fob124in place. According to some embodiments, retaining fence112may be spring loaded to provide pressure along at least one portion of key fob124, and to push key fob124into contact with both retaining fence112and an opposite-facing one of side portions120. Retaining fence112may take various other forms as well. First housing110may also include a locking mechanism116. Locking mechanism116may generally have one or more bolts or bearings that engage in a receiving portion such that, when the bolt is engaged in the receiving portion, the first and second portions of locking mechanism116may be lockably coupled. When the bolt is disengaged from the receiving portion, the bottom and top portions of locking mechanism116may removably engaged. Locking mechanism116may be affixed to one of side portions120, and may include any type of locking mechanism that is capable of securing first housing110with second housing150(illustrated inFIG.1C) such that the first housing110cannot be separated from second housing150without extraordinary effort or tampering. According to some examples, an actuator may operate locking mechanism116. One or more computing devices may control the actuator that operates locking mechanism116. FIG.1Bis a plan view of a single pin114A of pins114, an unattached pin cap134shown in isolation, and pin cap134shown connected or attached to a number of pins132. As illustrated by pin114A, pin114A may be cylindrically shaped with a tapered or semi-spherical head. Having a tapered or semi-spherical head may avoid the top of pin114A being stuck along an edge of key fob124when pin114A contacts key fob124. Generally, pins114may be made of metal, plastic, rubber, or any other material capable of depressing a button on a key fob. Pins114may take various other forms as well. The first housing110may include a variety of holes that extend through the top face of the bottom portion. The holes of first housing110would not extend all the way through to the bottom face (e.g., the first housing110may be solid or may be perforated). The holes may be substantially similar in diameter to the pins114such that a pin, when inserted into the hole, is removably engaged to the hole via friction or another locking mechanism. The pins can be removed by pulling the pin out of the hole such that the pins can be inserted into the bottom portion in any configuration as appropriate to the requirements of specific embodiments of the invention. InFIG.1B, pin cap134is illustrated as having an substantially oval shape for the purpose of example, but may have other shapes (e.g., circular, square, etc.) as well. The pin caps may come in a variety of shapes to accommodate different key fob button shapes. There may be more than one pin cap that may attach to pins114. Each pin cap may be attached to the pins below a corresponding key fob button. For example, a user may attach a pin cap to pins114beneath button126A, and may attach another pin cap to the region of pins114beneath button126B. The presence of a pin cap may enable a key fob button to be more accurately depressed when an actuator pushes the key fob downward toward an underlying pin cap. Because the pin caps (e.g., pin cap134) are removable, the pin caps may be re-attached to different groups of pins114to accommodate different key fob button positions. Turning now toFIG.1C, a perspective view of a second housing150of the same secure enclosure100holding or otherwise including key fob124in accordance with at least one embodiment is shown. Second housing150includes button actuators152A-152B (“button actuators152”), a top portion of locking mechanism116that latches with second portion of locking mechanism116, and a top portion158, which may be parallel to bottom portion118when secure enclosure100is latched shut. Second housing portion150also includes side portions160, which may be perpendicular to each other and may each also be perpendicular to top portion158. While side portions160are illustrated as being perpendicular (e.g., square) with each another, side portions160may also be oblique with respect to each other. Second housing150may include a sealing or weatherproofing mechanism (e.g., on sides portions160). FIG.1Cis illustrated from the perspective of key fob124being closest to the viewer, and buttons126of key fob124face the viewer. Button actuators152are positioned behind the backside of key fob124. Second housing150is adapted to fit with first housing110(FIG.1). According to some embodiments, second housing150may be coupled with first housing110with a hinge (not shown) or another coupling mechanism, fastener, or the like. Second housing150may be secured to first housing110with locking mechanism156. As illustrated inFIG.1C, second housing150includes two button actuators152A and152B. Although two button actuators152A and152B are illustrated, there may be any number of actuators. The number of button actuators included in top housing150may be based on a number of buttons of the object (e.g., key fob) enclosed within secure enclosure100. Button actuators152are illustrated as having a square shape for the purpose of example. However, it should be understood that button actuators152may be circular, elliptical, lobe-shaped, or any other shape that, when activated, may cause one or more buttons of key fob124enclosed within secure enclosure100to be depressed. A computing device may control the operation of button actuators152. The computing device may be communicatively coupled to each of button actuators152via one or more wires (not pictured) such that the computing device may activate each actuator. Additionally or alternatively, the button actuators may be wirelessly activated by the computing device via one or more wireless signals. When activated, one of button actuators152, such as button actuator152A, may exert a downward force on the back of key fob124, and specifically on the region of key fob124covered by button actuator152A. As a result of the downward force that the actuator (in this example, button actuator152A) exerts on key fob124, the front-facing region of key fob124corresponding to the region underneath button actuator152A is pressed into a corresponding region of one or more of pins114. Consequently, if key fob124includes a button, such as button126A, that is located underneath the actuated region, pins114would depress button126A. While button actuators152are illustrated as being partially aligned with buttons126A and126B inFIG.1C, the button actuators may or may not be exactly or nearly exactly aligned with the buttons. In order to accommodate a wide variety of key fob button configurations (e.g., different button positions and/or button shapes), the secure enclosure may accommodate a variety of second housings that each have different button actuator configurations in order to accommodate different key fob button configurations. For example, there may be a second housing150having three button actuators that are aligned vertically in order to accommodate a key fob having a corresponding button configuration. As another manner of accommodating different key fob button configurations, button actuators152may be repositioned and/or reconfigured in various manners. For instance, button actuators152may be added, removed, translated (e.g., moved horizontally or vertically) and/or rotated along top portion158. According to various embodiments, button actuators152may be repositioned along a grid on top portion158. Turning now toFIG.1D, a side perspective of the first and second housings of secure enclosure100holding or otherwise including key fob124in accordance with at least one embodiment is illustrated. InFIG.1D, secure enclosure100includes second housing150(as illustrated from a different perspective inFIG.1C) and first housing110(as illustrated from a different perspective inFIG.1A). First housing110and second housing150are shown as fitted together. The side portions of first housing110and second housing150nearest to the viewer are not shown for ease of visibility. Pins114are attached to first housing110, and button actuators152are attached to top portion158of second housing150. Second housing150and first housing110form a cavity130. Key fob124is illustrated within cavity130as secured by retaining fence112and resting face down on top of pins114. Button actuators152are in contact with the backside of key fob124. As illustrated by the arrows, when button actuator152A or152B is activated, the button actuator generates a force on the backside of key fob124. Button actuator152A is positioned over button126A of key fob124, and button actuator152B is positioned over button126B. When button actuator152A is activated, the force that button actuator152A imparts on key fob124causes one or more of pins114(which may be covered by an actuator cap) to depress button126A. Similarly, when button actuator152B is activated, the force of button actuator152B causes a different group of pins114(which may be covered by another actuator cap) to depress button126B. Turning now toFIG.2, a computing device200in accordance with at least one embodiment of the invention is shown. The computing device of secure enclosure100and/or a user computing device could both include one or more of the components described with respect toFIG.2. The computing device200can include a processor203for controlling overall operation of the computing device200and its associated components, including RAM205, ROM207, input/output device209, communication interface211, and/or memory215. A data bus can interconnect processor(s)203, RAM205, ROM207, memory215, I/O device209, and/or communication interface211. Input/output (I/O) device209can include a microphone, keypad, touch screen, and/or stylus through which a user of the computing device200can provide input, and can also include one or more of a speaker for providing audio output and a video display device for providing textual, audiovisual, and/or graphical output. Software can be stored within memory215to provide instructions to processor203allowing computing device200to perform various actions. For example, memory215can store software used by the computing device200, such as an operating system217, application programs219, and/or an associated internal database221. The various hardware memory units in memory215can include volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer-readable instructions, data structures, program modules or other data. Memory215can include one or more physical persistent memory devices and/or one or more non-persistent memory devices. Memory215can include, but is not limited to, random access memory (RAM)205, read only memory (ROM)207, electronically erasable programmable read only memory (EEPROM), flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to store the desired information and that can be accessed by processor203. Communication interface211can include one or more transceivers, digital signal processors, and/or additional circuitry and software for communicating via any network, wired or wireless, using any protocol including those described herein. According to some examples, communication interface211may include a wireless communication interface. The wireless communication interface may communicate with other computing devices via Bluetooth (e.g., Bluetooth Low Energy), satellite, GSM infrared, IEEE 802.11, WiMAX, RFID, cellular, and/or any suitable wireless communication media, standards, and protocols. Processor203can include a single central processing unit (CPU), which can be a single-core or multi-core processor (e.g., dual-core, quad-core, etc.), or can include multiple CPUs. Processor(s)203and associated components can allow the computing device200to execute a series of computer-readable instructions to perform some or all of the processes described herein. Although not shown inFIG.2, various elements within memory215or other components in computing device200, can include one or more caches, for example, CPU caches used by the processor203, page caches used by the operating system217, disk caches of a hard drive, and/or database caches used to cache content from database221. For embodiments including a CPU cache, the CPU cache can be used by one or more processors203to reduce memory latency and access time. A processor203can retrieve data from or write data to the CPU cache rather than reading/writing to memory215, which can improve the speed of these operations. In some examples, a database cache can be created in which certain data from a database421is cached in a separate smaller database in a memory separate from the database, such as in RAM205or on a separate computing device. For instance, in a multi-tiered application, a database cache on an application server can reduce data retrieval and data manipulation time by not needing to communicate over a network with a back-end database server. These types of caches and others can be included in various embodiments, and can provide potential advantages in certain implementations of software deployment systems, such as faster response times and less dependence on network conditions when transmitting and receiving data. One or more power sources (not pictured) may power computing device200. Batteries (e.g., lithium ion, nickel metal hydride, etc.), capacitors (e.g., super capacitors, ultra capacitors, etc.), energy harvesters (e.g., solar, thermal, etc.) may be examples of such power sources. The capacitor and/or energy harvester may charge a battery that can be used to power the computing device. Such capacitors may typically store and provide energy from 1 minute to 1 week. Such batteries may provide long-term energy storage when the energy harvesters are unable to provide enough energy to the capacitors to keep computing device200running. The one or more power sources may be mounted within secure enclosure100. Mounting the power source(s) within secure enclosure100may prevent tampering with the operation of secure enclosure100. Such power sources may be rechargeable (e.g., via USB, AC, or DC power sources). Although various components of computing device200are described separately, functionality of the various components can be combined and/or performed by a single component and/or multiple computing devices in communication without departing from the invention. As described above, a computing device, such as computing device200, may control various aspects and/or components of secure enclosure100. For instance, computing device200may control the operation of button actuators (e.g., actuators152), locking actuators (e.g., locking mechanism116), and may also communicate with other computing devices via a wireless connection. Operating Environments FIG.3illustrates an operating environment300in accordance with at least one embodiment of the invention. The operating environment300includes at least one client device310, at least one server system320, at least one vehicle330, at least one mobile computing device350, and/or at least one secure enclosure360in communication via a network340. Any of the devices and systems described herein can be implemented, in whole or in part, using one or more computing devices described with respect toFIG.3. Client devices310, server systems320, and/or mobile computing device350, may allow users to communicate with the at least one secure enclosure360, which may securely enclose a key fob for vehicle330. The network340can include a local area network (LAN), a wide area network (WAN), a personal area network (PAN), a wireless telecommunications network, and/or any other communication network or combination thereof. Secure enclosure360may receive a signal, having a payload including one or more messages, from another computing device described herein (e.g., client devices310, mobile computing device350, server system320) via a wireless communication interface. Such messages may be generated by a software application running on any of such computing devices. For example, secure enclosure360may receive such messages from a server system (e.g., server system320) or from mobile computing device350. The received messages may indicate an action that secure enclosure360is to perform. For example, such a message may instruct secure enclosure360to activate a given button actuator, such as actuator, or a locking actuator that controls locking mechanism. Such messages may take various other forms as well. In response to receiving such messages, a computing device of secure enclosure360may take the action indicated by the received message. According to various embodiments, secure enclosure360may authenticate the received messages before taking any such actions. Secure enclosure360may authenticate the received messages in various manners. According to some examples, a server (e.g., server system320) may be used to authenticate a message sender with secure enclosure360. In some instances, secure enclosure360may authenticate the sender of a received message using public key cryptography. For example, computing device and the sender of such messages may utilize TLS (Transport Layer Security), which uses X.509 certificates to authenticate a message sender. Secure enclosure360may authenticate message senders in various other manners as well. According to various embodiments, there may be multiple secure enclosures360, which one or more users may control. To allow such control over multiple enclosures, each secure enclosure may have its own certificate, which may be programmed onto each of secure enclosures360. To allow one user to control multiple secure enclosures, intermediate security certificates for the multiple enclosures may be generated. An intermediate certificate may allow a computing device in possession of an intermediate certificate's private key to authenticate with the multiple secure enclosures. According to various embodiments, secure enclosure360may store one or more maps of actuator locations and key fob button functions. Such maps may allow a user of secure enclosure to perform key fob functions that are stored in the maps. For instance, a key fob, such as key fob, may have multiple buttons. Each button may perform one or more functions. As an example, one button may unlock a single door of vehicle330if pressed once, and may unlock all doors of vehicle330if pressed twice in succession. Similarly, a given button may perform different functions depending on whether the button is pressed or held. However, users of secure enclosure who wish to use the key fob that is stored in the secure enclosure may be unaware of the button configuration of a key fob stored within secure enclosure, but may still wish to be able to use all the functions of that key fob. In order to make all the functions of a key fob stored within secure enclosure easily accessible to a user, mappings between a given function of a key fob and a corresponding actuator and activation time of that actuator may be maintained. In some examples, a computing device, such as client device310or mobile computing device350may maintain such mappings according to various embodiments. The application may, for example, display a mapping of key fob functions, for instance with a GUI (Graphical User Interface), which allows the user to select a given function to be performed by the secure enclosure. Based on receiving a selection, via the GUI, of selected function, the application may transmit a message to secure enclosure360indicating an actuator that is to be actuated and/or an amount of time (e.g., a duration) that the selected actuator is to be actuated in order to perform the indicated function. Secure enclosure360may receive the message and, based on the received message, may activate the selected actuator for the period of time specified in the message. In some embodiments, secure enclosure360may store such mappings of key fob functions. Secure enclosure360may activate a mapping based on receiving a message (e.g., from a computing device) indicating the map to be activated. Secure enclosure360may also receive a message from one of the computing devices disclosed herein that defines such a mapping. Based on such a message, secure enclosure360may store the mapping in a memory. Configuring and Operating Secure Enclosures FIG.4is a flow chart illustrating a process for configuring and using a secure enclosure in accordance with at least one embodiment. Some or all of the steps of process400may be performed using any of the computing devices and/or combination thereof described herein. In a variety of embodiments, some or all of the steps described below can be combined and/or divided into sub-steps as appropriate. At step410, a first user may place a key fob within a secure enclosure. The first user may place the key fob face down within the secure enclosure (e.g., first housing) such that the pins touch or contact the key fob and/or the key fob buttons. In some examples, the user may also select a second housing having a configuration of button actuators that corresponds to the key fob buttons. After placing the key fob inside the secure enclosure, the first user may use the retaining fence and the locking mechanism to lock the key fob inside the secure enclosure (e.g., by connecting the first housing to the second housing). The first user may also authenticate a first computing device, associated with the first user, with the secure enclosure (e.g., using TLS and/or X.509 certificates). Authenticating the first computing device with secure enclosure, may allow the first user to control the functionality of the secure enclosure (e.g., to actuate the key fob buttons and/or lock or unlock the enclosure) and to grant other users access to the functionality of the secure enclosure. At step412, the first user may use the first computing device associated with the first user to grant a second user, associated with a second computing device, wireless access to the secure enclosure. To grant the second user access to the secure enclosure, the first user may use the first computing device, for example, to send cryptographically signed credentials (e.g., X.509 certificates) to the secure enclosure or to the second computing device. Sending such credentials may allow the second computing device to prove that it has been granted access to use the functionality of the secure enclosure. At step414, the second user may use the second computing device to wirelessly actuate the key fob buttons of the secure enclosure, for example, to: start the vehicle, unlock the car doors, and/or perform various other actions with respect to the vehicle. The proximity of the key fob to the inside of the vehicle may allow the vehicle to be started without providing access to the key fob itself. The second user may actuate the key fob buttons via an application that runs on the second computing device, and causes the second computing device to send wireless messages to the secure enclosure. Based on receiving such wireless messages, the secure enclosure may activate one or more button actuators, thereby causing depression of a selected button on the key fob (e.g., via pins within the secure enclosure). At step416, the first user may decide to revoke the access privileges of the second user to the secure enclosure. To revoke such privileges, the first user may utilize the first computing device to send a message to the secure enclosure indicating that the second user's granted access privileges to the secure enclosure. Based on the message, the secure enclosure may then revoke the second user's access to control the secure enclosure. In some examples, user privileges may be automatically revoked upon expiration of a predetermined time period (e.g., one hour, one day, one week, or the like). FIG.5is a flow chart illustrating a process for configuring a secure enclosure in accordance with at least one embodiment. Some or all of the steps of process500may be performed using any of the computing devices and/or combination thereof described herein. In a variety of embodiments, some or all of the steps described below can be combined and/or divided into sub-steps as appropriate. At step510, the secure enclosure may receive, from a computing device, an authenticated message indicating a mapping of one or more actuators to one or more corresponding key fob functions. The mappings may define the functions of the key fob that occur when a given actuator is activated. For example, not every key fob may have a door unlock button in the same position. Such a mapping may define which actuator depresses a door unlock button of the key fob. At step512, the secure enclosure may generate a security certificate, or may receive a security certificate from another computing device. The security certificate may ensure that only authorized users may utilize the functionality of the secure enclosure. Operating Secure Enclosures FIG.6is a flow chart illustrating a process for operating a secure enclosure in accordance with at least one embodiment of the invention. Some or all of the steps of process600may be performed using any of the computing devices and/or combination thereof described herein. In a variety of embodiments, some or all of the steps described below can be combined and/or divided into sub-steps as appropriate. At step610, the secure enclosure may receive, from a computing device, an authenticated message indicating an actuator of the secure enclosure to be activated. The actuator may be one of the button actuators along the top portion of the secure enclosure, or a locking actuator that controls a locking mechanism in various examples. At step612, the secure enclosure may activate the indicated actuator based on the actuator indicated in the received message. For example, the secure enclosure may receive a message indicating a particular actuator is to be activated. Based on receiving the message, the secure enclosure may then activate the actuator. One or more aspects discussed herein can be embodied in computer-usable or readable data and/or computer-executable instructions, such as in one or more program modules, executed by one or more computers or other devices as described herein. Generally, program modules include routines, programs, objects, components, data structures, and the like that perform particular tasks or implement particular abstract data types when executed by a processor in a computer or other device. The modules can be written in a source code programming language that is subsequently compiled for execution, or can be written in a scripting language such as (but not limited to) HTML, JavaScript, or XML. The computer executable instructions can be stored on a computer readable medium such as a hard disk, optical disk, removable storage media, solid-state memory, RAM, and the like. As will be appreciated by one of skill in the art, the functionality of the program modules can be combined or distributed as desired in various embodiments. In addition, the functionality can be embodied in whole or in part in firmware or hardware equivalents such as integrated circuits, field programmable gate arrays (FPGA), and the like. Particular data structures can be used to more effectively implement one or more aspects discussed herein, and such data structures are contemplated within the scope of computer executable instructions and computer-usable data described herein. Various aspects discussed herein can be embodied as a method, a computing device, a system, and/or a computer program product. Although the present invention has been described in certain specific aspects, many additional modifications and variations would be apparent to those skilled in the art. In particular, any of the various processes described above can be performed in alternative sequences and/or in parallel (on different computing devices) in order to achieve similar results in a manner that is more appropriate to the requirements of a specific application. It is therefore to be understood that the present invention can be practiced otherwise than specifically described without departing from the scope and spirit of the present invention. Thus, embodiments of the present invention should be considered in all respects as illustrative and not restrictive. Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their equivalents. | 34,894 |
11859408 | DETAILED DESCRIPTION The following detailed description of embodiments includes references to the accompanying drawings, which form a part of the detailed description. Approaches described in this section are not prior art to the claims and are not admitted to be prior art by inclusion in this section. The drawings show illustrations in accordance with example embodiments. These example embodiments, which are also referred to herein as “examples,” are described in enough detail to enable those skilled in the art to practice the present subject matter. The embodiments can be combined, other embodiments can be utilized, or structural, logical and operational changes can be made without departing from the scope of what is claimed. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope is defined by the appended claims and their equivalents. Embodiments of this disclosure generally relate to opening devices for door locks. Some embodiments of the present disclosure solve issues of existing opening mechanisms for door locks. Certain embodiments of the present disclosure may allow arranging mechanisms for opening the door lock by an outside handle inside a building or room protected by the door. Therefore, these embodiments of the present disclosure may facilitate protecting the mechanisms for opening the door locks from outside attacks and attempts to break in, thereby increasing security of the door locks and preventing unauthorized access to the buildings and the rooms. According to an example embodiment, an opening device for a door lock may include a driver rigidly connected to an inside handle. The opening device may include an inside shaft designed to rotate an internal latching mechanism of the door lock. The opening device may include a first gear permanently engaged in rotation with the inside handle, thereby being permanently engaged rotationally with the driver. The inside shaft may have a follower and a through cavity. The opening device may include an outside shaft designed to be rotated by an outside handle. The outside shaft may include a cylindrical part disposed inside the through cavity of the inside shaft, a polyhedral part designed to be engaged with the outside handle, and a gear seat located at end of the cylindrical part and outside of the inside shaft. The opening device may further include a second gear designed to move along the gear seat and be engageable with the first gear. The first gear can slide along a direction toward the second gear. The inside handle may include an actuating mechanism to slide the first gear towards the second gear to engage with the second gear. The actuating mechanism may allow holding the first gear in engagement with the second gear. Additionally, the opening device may further include an engagement mechanism designed to cause the second gear to move along the gear seat to engage or disengage the first gear. When the second gear and the first gear are engaged and the outside shaft is rotated, the second gear causes the driver to engage the follower of the inside shaft, thereby causing the inside shaft to rotate the internal latching mechanism of the door lock. Referring now to the drawings,FIG.1Ashows an opening device100in assembly, according to an example embodiment. FIG.1Bshows exploded view of the opening device100, according to an example embodiment. The opening device100may include an inside handle102, an inside shaft120, an outside shaft112, a driver108, a follower114, a disk110, a tube128, a first gear116, a second gear118, an electrical magnet106, a rod142, a control dial146, a rod152, a blade148, a spring150, and a spring126. Driver108can be rigidly attached to the external circumference of disk110. The first gear116can be located at the center of disk110. The first gear116can be permanently engaged in rotation with the disk110. First gear116can slide along the direction of tube128. Tube128can be rigidly attached to disk110. Tube128can be rigidly attached to the inside handle102. Thus, when inside handle102is rotating, driver108rotates in the direction of rotation of the inside handle102. The control dial146can be rotated on the surface of the inside handle to cause the first gear116to slide along an internal cavity156of the tube128. To allow sliding of the first gear116in response to the rotation of control dial146, the first gear116may include a sloped back side154engaged with blade148. Blade148can be connected with control dial146via rod152. Both rod152and blade148can be located inside the internal cavity156of the tube128. When control dial146is turned in a first direction, first gear116moves towards second gear118. First gear116and second gear118remain engaged until control dial146is turned in a second direction opposite to the first direction. When control dial146is turned in the second direction, first gear116moves outward the second gear118, thereby disengaging second gear118. In another embodiment, opening device100may include a push button located on the surface of inside handle102. The push button can be engaged with first gear116. When push button is pressed, first gear116moves toward second gear118and engages with second gear118. First gear116and second gear118remain engaged until the push button is released. When the push button is released, first gear116moves away from the second gear118, thereby disengaging second gear118. The follower114can be rigidly connected to inside shaft120. The inside shaft120can be engaged with the internal latching mechanism of a door lock122. When driver108engages follower114and keeps rotating, it causes the inside shaft to rotate in the same direction as inside handle102. While rotating, inside shaft120can drive the internal latching mechanism to unlock the door lock122. In another embodiment, the opening device100may include an electro-mechanical motor (not shown) or an electrical magnet (not shown) inside the tube128of the inside handle102that can cause the first gear116to move toward the second gear118and engage the second gear118. The first gear116and the second gear118can be engaged until the electro-mechanical motor or the electrical magnet pull back the first gear116away from the second gear118. The opening device100may include a spring150designed to move second gear118away from first gear116when the electronic circuit stops providing the electrical current to the electrical magnet. The spring150can be located between first gear116and second gear118. The outside shaft112can be engaged and rotated with outside handle104. Lock-and-key mechanism130can be integrated into the outside handle104. Lock-and-key mechanism130can be designed to receive a door key (not shown) and can allow unlocking the outside handle104when the door key is rotated by a pre-determined angle. The inside shaft120may have a through cavity134. The outside shaft112may include a cylindrical part138, a polyhedral part140, and gear seat136. When the opening device100is in assembly, the cylindrical part138is disposed within through cavity134and the gear seat136is disposed outside the inside shaft120. When in the assembly, outside shaft112and inside shaft120can be allowed to rotate independently of each other around a common axis of rotation. Outside shaft112may have through cavity144. When the opening device100is in assembly, rod142is disposed within the through cavity144while a rod thickening124and a spring126are located outside. Rod thickening124can be located at the end of rod142. Spring126can be wound around rod142at rod thickening124. Second gear118can be designed to move along gear seat136of the outside shaft112. Second gear118can be engaged with first gear116of inside shaft120while still being engaged with gear seat136. The shape and number of gear teeth of first gear116, gear seat136, and second gear118can be different from shown inFIG.1AandFIG.1B. When second gear118is engaged with first gear116, rotation of the gear seat136(caused by rotation of outside shaft112) may cause rotation of first gear116, and, in turn, rotation of disk110and driver108. When driver108engages with follower114, it causes rotation of the inside shaft120, thereby opening the door lock122. When second gear118is not engaged with first gear116, rotation of outside shaft112will not result in rotation of first gear116, disk110, or driver108. To be engaged with first gear116, second gear118can be moved toward first gear116by an engagement mechanism. In some example embodiments, the engagement mechanism may include an electrical magnet106located around second gear118and between follower114and disk110. The engagement mechanism may further include an electronic circuit. The electronic circuit may include a receiver, a microprocessor, and a battery. The electronic circuit can provide an electrical current to the electrical magnet106in response to receiving a signal or a code. When electrical magnet106is provided with the electrical current, electrical magnet106generates a magnetic field forcing second gear118to move toward the first gear116and engage with it. The opening device100may include a spring150designed to move second gear118away from first gear116when the electronic circuit stops providing the electrical current to electrical magnet106. The spring can be located between first gear116and second gear118. In some example embodiments, the engagement mechanism may include an electro-mechanical motor to move second gear118either toward first gear116or away from first gear116. It should be noted that second gear118, first gear116, gear seat136, the engagement mechanism (including electrical magnets or electro-mechanical motors), drivers108, and follower114can be arranged on the unsecure side of a door, i.e., inside a building or a door protected by the door lock122. This arrangement allows lowering vulnerability of opening devices100against attacks from outside the building or the room. The second gear118can also be engaged with first gear116by door key (not shown) inserted into lock-and-key mechanism130. When inserted, the door key may push rod thickening124, thereby causing rod142to move along the through cavity144of outside shaft112and move the second gear118to be engaged with first gear116. In some embodiments, rod142can be rigidly connected to second gear118. In these embodiments, when the door key is pulled out from lock-and-key mechanism130, spring126may expand, allowing rod142to move second gear118away from first gear116to disengage second gear118and first gear116. In these embodiments, the spring126may also expand after the engagement mechanism (including electrical magnets106or an electro-mechanical motor) stops pushing the second gear118toward first gear116, thereby disengaging second gear118and first gear116. In some embodiments, rod142is not rigidly connected to the second gear118. In these embodiments, when the door key is pulled out from lock-and-key mechanism130, the spring150located between the first gear116and second gear118can move the second gear118and the first gear116away from each other. FIG.2is a view of an opening device100in a mode disallowing opening a door lock from outside, according to an example embodiment. InFIG.2, second gear118is not engaged with first gear116because, for example, the electrical magnet106is not provided with an electrical current to move the second gear118toward first gear116. Accordingly, rotation of outside shaft112cannot cause rotation of the first gear116, disk110, driver108, and inside shaft120. Therefore, door lock122cannot be unlocked from outside using outside handle104(shown inFIG.1A). At the mode disallowing opening a door lock from outside, the door lock122can be unlocked by rotating inside handle102. When the inside handle102rotates, it causes, via tube128and disk110, rotation of driver108. Driver108may engage with follower114to cause rotation of inside shaft120. The rotation of inside shaft120may cause the internal latching mechanism of door lock122to unlock the door lock122. In some embodiments, the opening device100may include a returning spring (not shown) disposed around follower114. The returning spring may expand and rotate the inside shaft120back to an initial position. FIG.3is a view of an opening device100in a mode allowing opening a door lock from outside, according to an example embodiment. InFIG.3, second gear118is engaged with first gear116by the electrical magnet106. Accordingly, rotation of outside shaft112may cause rotation of the first gear116, disk110, and driver108. As result, driver108may engage with follower114to cause rotation of inside shaft120. The rotation of inside shaft120may cause the internal latching mechanism of door lock122to unlock the door lock122. Therefore, door lock122can be unlocked from outside using outside handle104(shown inFIG.1A). Because inside shaft120can rotate independently on outside shaft112, the mode allowing opening door lock122from outside does not prohibit opening the door lock122from inside. The mechanism of opening door lock122from inside is described inFIG.2. FIG.4illustrates a method400for manufacturing an opening device for a door lock, in accordance with one embodiment. In some embodiments, the operations of method400may be combined, performed in parallel, or performed in a different order. The method400may also include additional or fewer operations than those illustrated. In block402, method400may include providing a driver rigidly connected to an inside handle. In some embodiments, method400may include providing a disk and a tube. The disk can be rigidly connected to the driver. The disk can be rigidly connected to the tube. The tube can be rigidly connected to the inside handle. In block404, method400may include providing an inside shaft designed to rotate an internal latching mechanism of the door lock. The inside shaft may have a follower and a through cavity. The follower can be designed to cause the inside shaft to rotate. In block406, method400may include providing an outside shaft designed to be rotated by an outside handle. The outside shaft may include a cylindrical part disposed inside the through cavity of the inside shaft, a polyhedral part designed to be engaged with the outside handle, and a gear seat located at end of the cylindrical part and outside of the inside shaft. In block408, method400may include providing a first gear. The first gear can be permanently engaged in rotation with the inside handle thereby being permanently engaged in rotation with the driver. The first gear can slide along an internal cavity of the tube toward the gear seat. In block410, method400may include providing a second gear designed to move along the gear seat and be engageable with the first gear. In block412, method400may include providing an engagement mechanism designed to cause the first gear and the second gear to be engaged or disengaged by moving the first gear along an internal cavity of the tube or moving the second gear along the gear seat. The engagement mechanism, the second gear, the driver, and the follower can be located on the unsecured side of a door (the side the door protects) or inside the door in which the door lock is integrated. The engagement mechanism may include an electrical magnet. The electrical magnet may cause the second gear to move toward the first gear. Alternatively, the electrical magnet may cause the first gear to move toward the second gear. In some embodiments, the electrical magnet may cause both the first gear and the second gear to move toward each other. In certain embodiments, the engagement mechanism may include an electro-mechanical motor. The electro-mechanical motor can move the second gear toward the first gear. Alternatively, the electro-mechanical motor can move the first gear toward the second gear. In some embodiments, the electro-mechanical motor can move both the first gear and the second gear toward each other. The engagement mechanism may include a spring causing the first gear and the second gear to move away from each other. When the first gear and the second gear are engaged and the outside shaft is rotated, the second gear causes the driver to engage the follower of the inside shaft, thereby causing the inside shaft to rotate the internal latching mechanism of the door lock. When the second gear is disengaged from the first gear, the driver stops to respond to rotation of the outside shaft. In optional block414, method400may include providing a rod. The outside shaft may have a further through cavity and the rod can be disposed within the further through cavity. The rod can be designed to push the second gear toward the first gear when a door key is inserted into a lock-and-key mechanism integrated into the outside handle. In optional block416, method400may include providing a spring designed to move the rod outward from the second gear when the door key is removed from the lock-and-key mechanism. FIG.5is a schematic diagram showing a control dial146and a first gear116engaged with a second gear118, according to an example embodiment. The control dial146may include an opening502. A user may use the opening502to rotate the control dial146. Specifically, the user may place a finger or a pin (not shown) inside the opening502and move the finger or the pin to rotate the control dial146. When the user rotates the control dial146in a first direction, the first gear116moves towards the second gear118and engages the second gear118. Specifically, the rotation of the control dial146moves the first gear116against the second gear118, thereby collapsing the spring150between the first gear116and the second gear118. The sloped back side154of the first gear116allows the movement of the first gear116when the control dial146is rotated. FIG.6is a schematic diagram showing the control dial146and the first gear116disengaged from the second gear118, according to an example embodiment. The first gear116and the second gear118remain engaged until the control dial146is turned in a second direction opposite to the first direction. When the user rotates the control dial146with a finger or the pin in the second direction, the first gear116moves away from the second gear118, thereby disengaging the second gear118. The rotation of the control dial146in the second direction enables the spring150to push the first gear116and the second gear118away from each other. Thus, an opening device for a door lock is described. Although embodiments have been described with reference to specific exemplary embodiments, it will be evident that various modifications and changes can be made to these exemplary embodiments without departing from the broader spirit and scope of the present application. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense. | 18,935 |
11859409 | REFERENCE NUMERALS 101, lock body base;102, lock cylinder hole;103, lock cylinder;104, key;105, push rod,106, fix frame;107, gear shaft;108, gear movable block;201, handle;202, connecting shaft;203, snap hole;301, electromagnet frame;302, electromagnetic coil;303, iron core;304, iron core spring,305, first permanent magnet;401, control circuit board;402, sensor switch;403, contact spring;501. reset tongue;502, reset lever;503, reset spring. DESCRIPTION OF THE EMBODIMENTS The technical solutions in the embodiments of the present disclosure will be clearly and completely described below in combination with the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present disclosure, rather than all the embodiments. Based on the embodiments in the present disclosure, all other embodiments obtained by those of ordinary skill in the art without creative work shall fall within the protection scope of the present disclosure. In order to facilitate the understanding of the present disclosure, an electronic lock used in industrial occasions may be described below. It can be understood that the control method of an electronic lock and the electronic lock based on the control method of the present disclosure are not only limited to this type of industrial locks, but can also meet the demand in more occasions where electronic locks are used. This should not be regarded as a limitation to the present disclosure, but should fall within the protection scope of the present disclosure. EMBODIMENT FIGS.1and10show schematic diagrams of a lock used in industrial occasions;FIG.1is a schematic diagram of the explosive structure of the lock.FIG.2is a schematic diagram of the overall structure of the lock when it is locked.FIG.3is a schematic diagram of the lock when the handle201is opened.FIG.4is a schematic diagram of the internal structure of the lock when it is locked.FIGS.5to10is enlarged schematic diagrams of the structure of Part A inFIG.4in various states of the lock.FIGS.11and12are schematic flow diagrams of the two control methods of the electronic lock. It can be seen that the lock may include a lock body base101and a handle201fixedly connected to the gear shaft107at the rear end of the lock body base101through a connecting shaft202. The handle201can be rotated based on the connecting shaft202, and can drive the gear movable block108to move up and down through the gear shaft107. The electromagnet, the reset tongue501and the reset spring503may be installed in the lock body base101through the fix frame106. The unlock mechanism composed of the lock cylinder103and the push rod105located at the rear end of the lock cylinder103and capable of moving up and down under its control may be installed in the lock cylinder hole102of the lower end of the lock body base101. A key104inserted into the lock cylinder103can drive the lock cylinder103to rotate to unlock. A control circuit board401with a sensor switch402may be installed in the lock body base101. The sensor switch402may have a contact spring403for sensing the movement of the push rod105. It can be understood that in this set of exemplary figures, one end of the handle201may be fixedly connected to the lock body base101through a connecting shaft202and a gear shaft107at the rear end of the lock body base101, and can rotate relative to the lock body base101based on the connecting shaft202. The lock may be connected to the gear movable block108through the gear shaft107, so that by turning the handle201to rotate the gear shaft107to drive the gear movable block108to move up and down to realize the opening of the cabinet door, this may be also a common feature of this type of lock. While in more occasions, the handle201can be can be completely independent from the lock body base101, and even the handle201may be simplified to be a structural member with only similar functions as the snap hole203directly installed on the door frame or cabinet door or directly made on the door frame or door panel, for example the handle201and the lock body base101may be separately installed on the cabinet door and on the door frame, and can be opened/closed by opening/closing the door and the door frame. All these should be regarded as the protection scope of this disclosure. It can be understood that, as shown in the group of exemplary figures, the manner that the lock cylinder103is rotated by a key104, and the rear end of the lock cylinder103drives the push rod105to move up and down driven by a gear can be adopted. The lock cylinder103and key used can be a mechanical lock cylinder103and a mechanical key, or can also be an electronic lock cylinder103and an electronic key. In practical applications, buttons or knobs can also be used to replace the lock cylinder103; The manner that the push rod105is driven to move up and down by pushing/pulling out the button or rotating the knob can be adopted. It can be understood that in this exemplary figures, the push rod105can move up and down under the control of the gear at the rear end of the lock cylinder103. In actual applications, the unlock mechanism and the push rod105controlled by it can also be realized in other ways, for example, a key hole can be opened under the lock body base101, the key104can be inserted directly into the key hole, the key can be inserted into the lower end of the snap hole203to realize the function of a push rod105. All these should be regarded as the protection scope of this disclosure. It can be understood that in this set of example figures, an electromagnetic coil302, an electromagnet frame301, a first permanent magnet305located in the electromagnet frame301, a telescopic body movable hole composed of a through hole of the electromagnetic coil302, a telescopic body composed of an iron core303in the through hole, and an electromagnet with a power-off self-holding function composed of a force applying structure composed of an iron core spring304located between the electromagnet frame301and the iron core303may be adopted. For ease of description, it may be defined that when the electromagnetic coil302of the electromagnet is energized in the forward direction, the electromagnetic coil302generates magnetic attraction to attract the iron core303to retract, and at the same time the iron core spring304is compressed; and after the power is off, the first permanent magnet305absorbs the iron core303and makes it maintain the retracted state; and when the electromagnetic coil302is energized in the reverse direction, the magnetic attraction generated by the electromagnetic coil302repels the first permanent magnet305, and the iron core303is stretched out due to the action of the compressed iron core spring304and cannot maintain the retracted state, after power is off, the extended state is still maintained. The electromagnet with this kind of function may have other construction methods. For example, the first permanent magnet305is located in the iron core303, by using the magnetic attraction generated by the first permanent magnet305and the electromagnet frame301themselves and the magnetic attraction or the magnetic repulsion generated by the electromagnetic coil302in the energized state to the first permanent magnet305, the iron core303can be extended or retracted and the state can be maintained. Alternatively, the iron core303may include a force applying structure composed of a second permanent magnet, and this function can also be realized by using the functions of the second permanent magnet and the first permanent magnet305in the iron core303. The differences in the structure and function of the electromagnet should be regarded as the protection scope of the present disclosure. Similarly, it can be understood that the first permanent magnet305can also be independently located in the lock body base101to perform the same function of “maintaining the retracted state when the telescopic body is retracted” as the first permanent magnet305located in the electromagnet. All these should be regarded as the protection scope of the present disclosure. It can be understood that the handle201may have a snap hole203for cooperating with the iron core303and the push rod105. The snap hole203may be an integral through hole; when the handle201is closed in the lock body base101, the telescopic body in the extended state can snap into the upper end of the snap hole203, and the push rod105located at the lower end of the snap hole203will not enter the snap hole203, as shown inFIG.4andFIG.5. It can be understood that when the push rod105is located outside the snap hole203and the electromagnet is energized in the forward direction, the iron core303can be moved upward and retracted. At this time, the iron core303may be separated from the snap hole203, and the handle201can be opened outwards with the shaft as the axis from the lock body base101, so as to realize the automatic opening of the electronic lock. The relevant structural diagrams may be shown inFIG.3andFIG.6. In order to overcome the accidental opening of the lock body when it encounters accidental vibration, etc., the necessary buckle structure may be added at the position where the lower end of the iron core303and the upper end of the snap hole203cooperate, which can better solve the above accidental opening. When the iron core303needs to move upwards, the buckle structure can be separated by lightly pressing the handle201, so that the iron core303can move upwards smoothly. All these should be regarded as the protection scope of this disclosure. It can be understood that in this set of example figures, when the key104is used to unlock the lock cylinder103, the push rod105may move upwards under the control of the lock cylinder103and enter the snap hole203from bottom to top. The upward movement of the push rod105will touch the contact spring403to trigger the sensor switch402, the push rod105may control the handle201to be unable to open, as shown inFIG.7. With the upward movement of the push rod105, when the upper end of the push rod105contacts the iron core303, the push rod105that continues to move upward will push the iron core303upward together, thus the iron core303may be retracted relative to the electromagnetic coil302, and the iron core spring304may be compressed, as shown inFIG.8. At this time, the push rod105may still trigger the contact spring403. when the push rod105moves downward with the control of the lock cylinder103, it will finally be separated from the snap hole203follow as the push rod105moves downward, if the iron core303remains retracted at this time, both the iron core303and push rod105may be separated from the snap hole203, and the handle201can be opened from the lock body base101, the related structure diagram may be shown inFIG.6. If the electromagnetic coil302is energized in the reverse direction before the push rod105moves down and detaches from the snap hole203, the iron core303cannot be kept retracted, so that the iron core spring304will make the iron core303stick out and enter the snap hole203, as shown inFIG.7andFIG.10. Even if the push rod105continues to move downward and detach from the snap hole203, because the iron core303may be still in the snap hole203, the handle201still cannot be opened from the lock body base101, and the relevant structure diagrams may be shown inFIG.4andFIG.5. It can be understood that, in this solution, the snap hole203can also be divided into an upper snap hole matched with the iron core303and a lower snap hole matched with the push rod105. When the iron core303is extended downward, it may be snapped into the upper snap hole; when the push rod105moves upward, it may be snapped into the lower snap hole. The upper snap hole and the lower snap hole may be communicated or not communicated at all. After the push rod105moves upward, it may retract the iron core303through other mechanical structures outside the lower snap hole. Depending on the structure of the snap hole203and iron core303, the corresponding push rod105and iron core structure can also be different, but their core function “the push rod105is controlled by the unlock mechanism to move up and down”, and the basic function “when the push rod105in the extended state is located in and moves upwards in the snap hole203, it can push the telescopic body upwards” will not change. All these should be regarded as the protection scope of this disclosure. It can be understood that in this solution, when the electronic lock is locked, the lower end of the iron core303in the extended state may be clamped into the snap hole203, thereby controlling the handle201. In practical applications, blocks with different mechanical structures can also be connected to the lower end of the iron core303, the handle201can be controlled through the block and the snap hole203on the handle201or the clamping groove with similar structure. While there may be many types of mechanical structures that the block is pushed by the push rod105to drive the iron core303to retract, and there may be no change in the fundamental functions between the handle201and the push rod105. All these should be regarded as the protection scope of this disclosure. It can be understood that in this set of schematic diagrams, in the process of preventing illegal unlocking with a key104, it may be only necessary to prevent the iron core303from being retracted and extend into the snap hole203when the push rod105remains in the snap hole203. If the power consumption of the electronic lock is not considered when illegal unlocked by the key104, as shown inFIG.7, when the push rod105moves upward and the sensor switch402is triggered, the electromagnetic coil302may start and remain to be energized in the reverse direction. At this time, the push rod105may continue to move upward, then the iron core303may be pushed up and retracted, as shown inFIG.8. But the iron core303cannot maintain the retracted state, and as the push rod105moves downward, the iron core303will move downward together and continue to be locked into the snap hole203, as shown inFIG.7. While the push rod105continues to move downwards to release the trigger state of the sensor switch402, the electromagnetic coil302may be cut off, and the iron core303may be still in the snap hole203, as shown inFIG.10. When the push rod105exits the snap hole203, the handle201cannot be opened. During the whole process, as long as the key104drives the lock cylinder103to move the push rod105and trigger the sensor switch402, the electromagnetic coil302needs to be energized in the reverse direction and maintained, and continues until the sensor switch402is released from the trigger state, that is, the push rod105returns to its original state. The flow chart of the control method of the electronic lock may be shown inFIG.11. It can be understood that in the above solution, if it may be necessary to further consider how to reduce the power consumption of the electronic lock when illegal unlocked by the key104, then it may be necessary to consider how to further reduce the problem of how to control the electromagnetic coil302power supply when illegal unlocked by the key104. A control method of an electronic lock that may be further optimized under the above technical conditions, as shown inFIG.12, it is the flow chart of the control method. After the push rod105moves up and enters the snap hole203, the push rod105may continue to rise and trigger the sensor switch402, at this time, the electromagnetic coil302may be temporarily not energized, as shown inFIG.7. While the push rod105continues to move upward and push the iron core303upwards together and make the iron core303exit the snap hole203, the iron core303may retract relative to the electromagnetic coil302, as shown inFIG.8. When the push rod105is controlled by the lock cylinder103and starts to move downwards, the electromagnetic coil302may still remain power-offed, and the iron core303may remain retracted, as shown inFIG.9. When the push rod105continues to move downward in the snap hole203and at the moment when the sensor switch402is released, the push rod105may be still located in the snap hole203. At this time, when the electromagnetic coil302is energized in the reverse direction, the iron core303in the retracted state may extend downward and snap into the snap hole203. As shown inFIG.10, the electromagnetic coil302can be de-energized after that. When the electromagnetic coil302is energized and the iron core303is stuck in the snap hole203, the push rod105that continues to move downward may be still located in the snap hole203; and when the push rod105continues moving downwards and exiting the snap hole203, the iron core303may remain coupled in the snap hole203, thereby controlling the handle201. The relevant structural diagrams may be shown inFIG.4andFIG.5. In this way, only after the push rod105moves down to a certain position in the snap hole203, the electromagnetic coil302may be instantly energized to achieve the above functions, which greatly reduces the problem that the power consumption of the electronic lock when the key104is inserted into the lock cylinder103to unlock. In order to better realize the above functions, it may be necessary to lengthen the length of the snap hole203to increase the distance of the push rod105moving in the snap hole203, so in the process that the push rod105moves downward and the sensor switch402is deactivated until the push rod105of completely exiting the snap hole203, there may be enough time for the control system of the electronic lock to react, and the electromagnetic coil302may be energized and the iron core303can be extended and stuck into the snap hole203. All these should be regarded as the protection scope of this disclosure. It can be understood that in this set of exemplary figures, a reset tongue501and a reset spring503may be also installed in the lock body base101. The lower end of the reset tongue501may abut against the outer wall of the snap hole203of the handle201when the handle201is closed in the lock body base101, and can make the reset spring503in a compressed state, as shown inFIG.4. When the iron core303is retracted, the ejector rod at the upper end of the iron core303may extend from the upper end of the through hole of the electromagnetic coil302and may be not affected by the reset rod at the upper end of the reset tongue501. When the handle201is opened from the lock body base101, the reset tongue501may lose the support of the handle201and can move downward under the action of the reset spring503. The reset rod may push the iron core303to move downward, so that the iron core303can extend downward, as shown inFIG.3. It can be understood that the reset tongue501structure with this type of function can have many forms, for example, the reset tongue501may directly abut on the inner wall of the handle201, and after the handle201is separated from the lock body base101, the reset spring503may push the reset tongue501to move, so as to achieve the purpose of extending the iron core303in the retracted state through the reset tongue501. It can be understood that through the different structures of the iron core303, combined with the different structures of the reset tongue501, this purpose can also be achieved. For example, when the reset tongue501directly moves downwards, it can directly push the snap ring outside the electromagnetic coil302at the lower end of the iron core303, the purpose can be also achieved. For different processing methods, the structures of the reset tongue501and the reset spring503themselves can be changed, but their core function may be still “when the telescopic body is in a high position and the handle201is separated from the lock body base101, the reset spring503pushes the reset tongue501to make the telescopic body move downward”. All these should be regarded as the protection scope of this disclosure. It can be understood that in this solution, the sensor switch402may be a light-touch switch with a contact spring403, and the switch may be triggered by triggering the contact spring403, so that the electrical signal output by the switch changes. In practical applications, the sensor switch402can also be an electromagnetic sensor switch, or a contact switch, or a light-sensitive sensor switch, or a micro switch. It can also be a sensor switch set composed of a plurality of sensor switches, or even a plurality of sensor switches of different types, which may be convenient for more precise sensing the position of the push rod105and the status of the push rod105moving upwards or downwards. The sensor action performed by the sensor switch402to the unlock mechanism for unlocking operations can be that the sensor switch402is triggered to send an electrical signal to the electronic lock control system, or that the switch is restored from the triggered state to the non-triggered state so that the electronic lock control system loses the electrical signal. All these should be regarded as the protection scope of this disclosure. It can be understood that, in this solution, an sensor switch may be adopted to sense the movement of the push rod105, but in fact, one or more sensor switches can be used to sense the unlocking operation by the unlock mechanism. The one or more sensor switches may sense the upward/downward movement of the push rod105, or sense upward/downward movement of the telescopic body, or sense the upward/downward movement of the reset tongue501by the unlock mechanism or push rod105, or sense the actions including insertion of the unlocking key, rotating the lock cylinder103or knob on the handle201, or pressing the button. Alternatively, the one or more sensor switches may be used to sense the unlocking operation by the unlock mechanism, which refers to that the upward movement of the push rod105or the upward movement of the reset tongue501can cause one or more sensor switches to be triggered, when the push rod105or the reset tongue501moves down, one or more of the sensor switches may be triggered to return to the state when it is not triggered; or it refers to that after the upward movement of the push rod105or the upward movement of the reset tongue501makes one or more sensor switches untriggered, one or more of the sensor switches may be triggered when the push rod105or reset tongue501moves downward. All these should be regarded as the protection scope of this disclosure. It can be understood that, in this set of exemplary figures, the sensor switch402may be installed on the circuit board, and the circuit board may be installed in the lock body base101. When the sensor switch402is triggered/untriggered after obtaining the unlock mechanism to perform the unlock action, it will enable the control circuit board401to obtain relevant electrical signals, so that the control circuit board401can determine whether the unlock action of the unlock mechanism is illegal. If it is determined to be an illegal unlock action, the electromagnetic coil302will be energized in the reverse direction or kept reversely energized. If it is determined as a legal unlock action (network interruption, or equipment failure, or obtaining a legal unlocking authorization, etc.), the electromagnetic coil302may be energized or cut off. And if the circuit board itself has an electrical failure (including the failure of the sensor switch402), the electromagnetic coil302will not be energized in the reverse direction or remain reverse energized, and the lock can still be unlocked by the unlock mechanism. In practical applications, the sensor switch402can also be separately installed in the lock body base101as required, and then electrically connected to the circuit board, and the circuit board can also be installed outside the lock body base101as required. In this regard, the specific installation position of the sensor switch402and the installation position of the circuit board should be regarded as the protection scope of the present disclosure. It can be understood that in this embodiment, in order to further enhance the mechanical strength of the electronic lock when it is locked, a block can be added to the end of the iron core303, so that the block may replace the iron core303to buckle the snap hole203. When the push rod105moves upward, the iron core303may be driven to move upward together by pushing the block, so that the above technical solution can also be realized. All these should be regarded as the protection scope of this disclosure. The control method of an electronic lock and the electronic lock based on the control method of the present disclosure have a simple structure. The telescopic body of the electromagnet located on the lock body base101and the push rod105controlled by the unlock mechanism jointly control the snap hole203on the handle201. The first permanent magnet305may be used to make the telescopic body of the electromagnet have the characteristics of self-holding function when power off, which not only solves the automatic unlocking function that electronic locks need to have, but also solves the hidden danger of illegal unlocking through mechanical structures. It can greatly reduce the power consumption of electronic locks when preventing illegal unlocking, and can meet the market's technical requirements for electronic locks, and has high promotion value. However, the above are only preferred and feasible embodiments of the present disclosure, and do not limit the scope of protection of the present disclosure. Therefore, all equivalent structural modifications made by using the concepts of the specification and drawings of the present disclosure are included within the range in the protection of the present disclosure. INDUSTRIAL APPLICABILITY The control method of the electronic lock and the electronic lock based on the control method of the present disclosure have a simple and reliable electronic lock structure. The unlock tool, the electromagnet and the first permanent magnet are used cleverly, and the unlock tool and the telescopic body of the electromagnet are used together to control the snap hole of the lock body, which realizes automatic unlocking and preventing illegal unlocking. At the same time it can meet the purpose of unlocking the lock through the unlock mechanism when any electronic failure occurs; and through the unique control method, the low power consumption of the electronic lock can be further realized. It has high application value in the application of electronic locks. | 26,596 |
11859410 | DETAILED DESCRIPTION FIGS.1and2illustrate an example vertical door assembly20, such as a rollup or overhead style door. The vertical door assembly20includes a plurality of slats22that are rotatably connected to each other along their length and slideably connected to a first vertical guide rail24and a second vertical guide rail26along respective opposite ends of the slats22. In the illustrated example, the vertical door assembly20is used to selectively enclose an opening in a wall28and secure the opening in the wall through the use of a bolt assembly60. The plurality of slats22include an interior surface36(FIG.1) that faces towards an enclosed space and an exterior surface38(FIG.2) that faces away from the enclosed space. The wall28could be a wall locating a building, a shipping container, a trailer, or any other type of arrangement where it is desirable to selectively enclose an opening in a structure. The vertical door assembly20includes a tension wheel assembly30having a drum31supported by an axle34to allow the plurality of slats22to move through the first and second guide rails24,26and collapse into a closed position. The tension wheel assembly30allows the plurality of slats22to roll around the axle34about an axis of rotation A to store the plurality of slats22above the opening in the wall28. Additionally, the tension wheel assembly30could be spring loaded to reduce the force needed to raise the plurality of slats22. In the illustrated example, the axle34is supported relative to the wall28through a bracket32located adjacent opposite ends of the axle34and fixed relative to the wall28. FIGS.3-5illustrate an enlarged views of the example bolt assembly60. In the illustrated example, the bolt assembly60includes a bolt housing62formed from a cover or first portion62A and a back or second portion62B that both at least partially define an interior cavity63(FIG.5) within the bolt assembly60. The back portion62B includes a back surface that is at least partially in engagement with the exterior surface38one of the slats22as shown inFIG.2. The front portion62A also includes a front flange72A that at least partially engages a back flange72B on the back portion62B. The front and back flanges72A,72B also completely surround the cavity63and each include corresponding fastener openings74A,74B that are used to secure the front and back portions62A,62B to each other and to one of the slats22(FIGS.3-6). The bolt assembly60also includes a bolt64, which is slidable relative to the bolt housing62to allow the bolt64to engage an aperture58(FIG.1) in the first vertical guide rail24to prevent the plurality of slats22from moving relative to the first and second vertical guide rails24,26. In the illustrated example, the bolt64includes a bolt handle66that allows a user to manually move a distal end or catch portion of the bolt64horizontally into and out of the aperture58in the first vertical guide rail24. The handle66also extends from the bolt64in the cavity63through a handle aperture67defined the first portion62A. The bolt64also extends through a bolt sleeve65on the back portion62B. The sleeve65provides additional protection to the bolt64to prevent unwanted tampering with the bolt assembly60. Additionally, the handle66is attached to the bolt64through the use of a fastener69(FIG.4), such as a screw. A strength of the fattener69is chosen to allow the handle66to separate from the bolt64if excessive force is applied to the bolt64that would indicate that the bolt assembly60is being forced open. Furthermore, if the handle66is separated from the bolt64, the bolt assembly60can be serviced to allow the new handle66to be attached to the old bolt64with a new fastener69or to allow the bolt64and handle66to be replaced entirely. Furthermore, this disclosure also applies to the bolt assembly60being located adjacent the second vertical guide rail26. The aperture58could be located separate from one of the first or second vertical guide rails24,26and be located in the wall28or another structure that is fixed relative to the wall28. As shown inFIG.5, the bolt assembly60includes an electronic control module70in electrical communication with an actuator lock assembly68(FIG.12) to selectively secure the bolt64when in a locking position or release the bolt64when in a non-locking position as will be described further below. In the illustrated example, the electronic control module70includes a printed circuit board in communication with memory70A, a processor70B, a wireless communications device70C, and at least one indicator light70D. The memory70A is preprogrammed and in communication with the processor70B, such as a controller, to perform the operations described below. In one example, the wireless communications device70C is capable of forming a Wi-Fi or Bluetooth connection to transfer a desired locked or unlocked request from a user wirelessly to the wireless communications device70C to change an operating state of the actuator lock assembly68. The electronic control module70may also utilize the at least one indicator light70D to display a connection status with the user formed with the wireless communications device70C and/or a locked status of the bolt64relative to the bolt housing62. The electronic control module70is in electrical communication with a battery assembly82to provide power to the electronic control module70. The electronic control module70also monitors a position of the bolt64, battery assembly82and, and vertical door assembly20. To monitor a position of the bolt64, the electronic control module70includes a first bolt sensor70F and a second bolt sensor70E. When the sensor70F is active, the bolt64is in the locked position and when the sensor70E is active, the bolt64is in the unlocked position. Alternatively, only one of the first and second bolt sensors70F,70E are used to confirm that the bolt64is locked or in another position. The electronic control module70can utilize the wireless communications device70C to transmit to a remote location the status of the bolt64. This allows a user at a remote location to be notified if the bolt assembly60is unlocked for a greater than expected time indicating that the vertical door assembly20may not be secured or that the vertical door assembly20may no longer be in use by an occupant of storage space. The electronic control module70is also includes a sensor70I, such as an accelerometer, that can determine when the vertical door assembly20is in an open or closed position and communicate this information to a user as the remote location80if the vertical door assembly20is in an open location beyond a predetermined length of time. Regarding the battery assembly82, the first battery sensor70G is active when the battery assembly82is removed from the housing62and the second battery sensor70H is active when the battery assembly is locked. This information can also be communicated to the remote location80through the wireless communications device70C. Information regarding the position of the battery assembly, opening of the vertical door assembly, and position of the bolt64can be logged by the remote location to maintain a history of activity at the vertical door assembly and with the bolt assembly60. In addition, information regarding a lever of battery charge can be transmitted to the remote location to determine when the battery assembly82needs to be charged or replaced. FIGS.6and7illustrate the bolt assembly60attached to a plurality of slats22A. In the illustrated example, the plurality of slats22A include four fastener openings75A that correspond to the fastener openings74A,74B in the bolt assembly60. When the back portion62B is located within a recessed portion of the slats22, an upper and lower portion of the back flange72B sits flush against and in directed contact with the portion of the slats22A having the fastener openings75A. Fasteners77can then secure the bolt assembly60to the slats22A and extend through a backer plate88A in contact with an interior surface36A of the slats22A. One feature of the backer plate88A is to provide an engagement surface for the fasteners77that distributes the load of the fasteners77over a larger area of the slats22to prevent the fasteners77from pulling through the slats22A and separating the bolt assembly60from the vertical door assembly20. Alternatively, as shown inFIGS.8-11, when the bolt assembly60is used with a plurality of slats22B having a two-hole configuration with a pair of spacers90to position the bolt assembly60relative to the slats22B. The spacers90includes a bolt assembly contact side91and a slat contact side92opposite the bolt assembly contact side91. The bolt assembly contact side91of the spacer90includes a surface that contacts both a portion of back flange72B and a central region of the back portion62B that fits within a recessed area of the slats22B. The slat contact side92includes a surface that contacts the slat22B and an end wall93at each opposing end of a first wall96and a second wall97. The end walls93and the first and second walls96,97form a cavity94with the slats22B. The first wall96includes a lip98along an outer edge that extends between the end walls93that directly contacts the slats22B. The spacer90also includes fastener openings95that accept fasteners77extending through fastener openings74A,74B in the bolt assembly60. Therefore, the fasteners77secure the bolt assembly60to the spacers90and not the slats22B. Fasteners79secure the bolt assembly60to the slats22B by extending through fastener openings74C (FIG.4) in the back portion62B of the bolt assembly60into a backer plate88B in contact with an interior surface36B of the slats22B. One feature of the backer plate88B is to provide an engagement surface for the fasteners79that distributes the load of the fasteners79over a larger area of the slats22B to prevent the fasteners79from pulling through the slats22B and separating the bolt assembly60from the vertical door assembly20. FIGS.12-15illustrate a method of locking and unlocking the bolt64with the actuator lock assembly68. In the illustrated example, the actuator lock assembly68includes a lead screw102driven by the drive motor100, a blocker plate104configured to selectively allow movement of a pin106into and out of locking engagement with the bolt64, and a spring108engaging a slider nut110at a first end of the spring and the blocker plate104at a second end of the spring. As shown inFIG.12, when the bolt64is in a locked position relative to the back portion62B, the blocker plate104is positioned such that the pin106is located in a pin opening112in the back portion62B and a pin opening114in the bolt64. To allow the bolt64to move relative to the back portion62B, the motor100rotates the lead screw102in a first direction to draw the sliding nut110and the blocker plate104towards the motor100. The lead screw102extends through both first and second ends110A,110B of the sliding nut110and first and second ends104A,104B of the blocker plate104, respectively. Additionally, the second end110B of the sliding nut110is in an overlapping relationship with the first end104A of the blocker plate104along the lead screw102such that the second end110B of the sliding nut110pulls the blocker plate104towards the motor100when the lead screw rotates in the first direction. Furthermore, the first and second ends104A,104B of the blocker plate104slidably engages the lead screw102while at least one of the first or second ends110A,110B of the sliding nut threadably engage threads on the lead screw102. The blocker plate104includes a connecting portion104C connecting the first and second ends104A,104B. The sliding nut110also includes a connecting portion110C that extends between the first and second ends110A,110B and engages the back portion62B to prevent the sliding nut110from rotating relative to the back portion62B. However, the sliding nut110could travel through a track in the back portion62B or engage another structure to prevent it from rotating with the lead screw102. To release the bolt64relative to the back portion62B, the pin106must align with a pin recess116in the connecting portion104C of the blocker plate104. In the illustrated example, the pin recess116is defined by the connecting portion104C of the blocker plate104and an arm118extending from the blocker plate104. The arm118creates sufficient space for the pin106to fit between the bolt64on a first side and the arm118on a second opposite side. The pin106is at least partially located in the pin opening112in the back portion62B in both the locked or unlocked position. Furthermore, the configuration in the illustrated example allows the blocker plate104to be manufactured by stamping from a single piece of material. To lock the bolt64relative to the back portion62B while the bolt64is still in a retracted position, the motor100drives the lead screw102in a second or opposite direction to move the sliding nut110and the blocker plate104away form the motor100. Because the bolt64is still in a reacted position inFIG.14, the pin106prevents the blocker plate104from moving to a fully extending position by engaging the arm118. Because the sliding nut110and the blocker plate104are in an overlapping relationship with the spring108, the sliding nut110compresses the spring108against the blocker plate104. The compressed spring provides a biasing effect on the blocker plate104such that the blocker plate104will push the pin106back into the pin opening114in the bolt64when the bolt is moved to an extended position. As shown inFIG.15, the spring loaded or biased position of the blocker plate104creates a gap or spacing between the second end110B of the sliding nut110and the first end104A of the blocker plate104. Once the bolt64is moved to an extended position, the pin106engages both the pin opening114in the bolt64and the pin opening112in the back portion62B to lock the bolt64as shown inFIG.12. The spring108also expands in axial length such that the second end110B of the sliding nut110engages the first end104A of the blocker plate104. The control module70can selectively drive the motor100to varying positions as described above based on signals from a user or remote location80(FIG.5). During operation of the bolt assembly60, a user communicates with the electronic control module70through the wireless communications device70C to position the bolt assembly60in a locked or unlocked position. Additionally, the electronic control module70can move the bolt assembly into a locked position or a ready to be locked position after a predetermined length of time to prevent a user from inadvertently leaving the bolt assembly unlocked. The communication between the user and the wireless communications device70C may occur through an application or web interface on a user's mobile device through a Bluetooth or other type of wireless connection. Additionally, the electronic control module70can store a record of the user that accessed the wireless communications device70C on the memory70A on the electronic control module70. The record can include the identity of the user based on the device used to access the wireless communications device70C and the time of the request. Alternatively, the electronic control module70can send the record to a remote location80(FIG.5) through use of the wireless communications device70C to monitor access through the vertical door assembly20. Additionally, the remote location80can send a signal to the electronic control module70through the wireless communications device70C to direct the actuator lock assembly68to move between one of the locked or unlocked position. Additionally, the wireless communications device70C can form a wireless connection with a gateway81that communicates to the cloud83through another wireless connection. The wireless connection in communication with the cloud83might include a wireless communication method such as Wi-Fi, Long Range BRLE, LoRaWAN, sub-gig hz, SIG-FOX, or NBIOT. One feature of these wireless communication methods is the ability to transmit information over long distances which is helpful in areas with poor cellular service. Additionally, the wireless communication method might be a one-way communication or a two-way communication such that the wireless communication device70C with receive messages or information from the wireless communication method. The wireless communications device70C could communicate information including who unlocked the bolt assembly60, when and how long the bolt assembly60was left unlocked, if the bolt assembly60is still left unlocked such that this information could be stored in the cloud83to monitor operation of the bolt assembly60. If any of the information obtained from the wireless communication device70C is outside of predetermined parameters, a message could be sent through the cloud to a person responsible to manage access through the vertical door into the storage space. Although the different non-limiting examples are illustrated as having specific components, the examples of this disclosure are not limited to those particular combinations. It is possible to use some of the components or features from any of the non-limiting examples in combination with features or components from any of the other non-limiting examples. It should be understood that like reference numerals identify corresponding or similar elements throughout the several drawings. It should also be understood that although a particular component arrangement is disclosed and illustrated in these exemplary embodiments, other arrangements could also benefit from the teachings of this disclosure. The foregoing description shall be interpreted as illustrative and not in any limiting sense. A worker of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure. For these reasons, the following claim should be studied to determine the true scope and content of this disclosure. | 18,019 |
11859411 | The locking system shown inFIG.1comprises a portable lock10in the form of a hoop lock comprising a U-shaped closing hoop12whose ends are received in a lock body14and locked therein in a locked state of the lock10. The locking of the closing hoop12in the lock body14takes place by means of locking elements16that are movably supported in the lock body14, that engage in corresponding locking recesses18of the closing hoop12, and there thereby prevent the closing hoop12from being able to be pulled out of the lock body14. To unlock the lock10, the locking elements16can be released, for example against the return force of locking springs that are not shown and that preload the locking elements in the direction of the locking recesses18, from the locking recesses18by means of an unlocking motor20, here in the form of an electric motor, that is arranged in the lock body14. Since the locking of the closing hoop12in the lock body14is effected by the locking springs that displace the locking elements16into the locking recesses18and since the unlocking motor20ultimately only provides the unlocking of the lock10, the lock10is also called a semi-automatic lock10. A fully automatic lock is, however, generally also conceivable in which the unlocking motor20provides both the unlocking and the locking. An energy store22is accommodated in the lock body14for the energy supply of the electric motor20. In the present embodiment, the energy store22is a rechargeable battery that can be charged by means of a connector element, here in the form of a USB socket, that is accessible from the outside. Alternatively, however, the energy store22could also be a battery that can be replaced as required. An actuation element26that is accessible to the user is provided at the lock body14for the triggering of an unlocking procedure and is configured in the present embodiment in the form of a capacitively acting sensor surface. Alternatively, the actuation element26could also be an optically acting or inductively acting control or a rotatable knob, a push button, a rocker switch, or slider switch. It is furthermore conceivable to configure the actuation element26in the form of a motion sensor. The actuation of the actuation element26would in this case take place by a movement of the lock10. The actuation element26is connected to an authentication module28that is accommodated in the lock body14and that is in turn connected to the electric motor20. The authentication module28is activated by actuating the actuation element26so that the authentication module28carries out an authentication process. For this purpose, the authentication module28first establishes a Bluetooth connection by means of a transmission/reception unit29to a mobile end device30that a user of the lock10carries with him for this purpose. In the present embodiment, the mobile end device30is a Bluetooth enabled remote control (see alsoFIG.2) that in turn has a transmission/reception unit31and that can be switched on by means of a switch-on element32. The remote control can also have a motion sensor, not shown, for example a 3D positional sensor, for detecting a movement of the remote control that makes it possible to wake up the remote control on detection of a movement after it has changed into an energy-saving passive state after its use. Alternatively, the mobile end device30could, however, also be formed by a smart watch, a smartphone, or another Bluetooth enabled portable computer. As soon as the authentication module28has established a Bluetooth connection to the mobile end device30, it carries out an authentication of the mobile end device30. In the event of a positive authentication, the authentication module28transmits a release signal to the electric motor20so that is can move the locking elements16and the closing hoop12out of engagement for the unlocking of the lock10. If, in contrast, the mobile end device30is not positively authenticated, the authentication module28does not transmit a release signal to the unlocking motor20, i.e. the lock10is not unlocked and can thus not be opened by the user. If the actuation element26is configured in the form of a motion sensor, the authentication module28can be connected to an alarm module, not shown, that outputs an alarm, in particular an acoustic alarm, to protect against theft in the event of a detected movement of the lock10and of an unsuccessful authentication procedure. It is understood that both the authentication procedure and the actual unlocking procedure require that the energy store22has sufficient energy. For the case that the energy store22is so discharged that an authentication and/or an unlocking is no longer possible, the mobile end device30has an emergency energy store34, for example in the form of a power bank, and a connector element36, here in the form of a USB plug, complementary to the connector element24of the lock10to connect the emergency energy store34of the mobile end device30to the connector element24of the lock and to charge the energy store22of the lock10at least so much that the authentication can be carried out and the lock10can be unlocked. To protect the connector element36of the mobile end device30from contamination and/or damage, the connector element36can be retracted by a slider37into a housing38of the mobile end device30(FIG.2D) and can be extended out of it again as required (FIG.2C). A second embodiment of the locking system is shown inFIG.3that only differs from the above-described first embodiment in that the mobile lock10is here not a hoop lock, but rather a frame lock attached to a frame40of a bicycle42. This frame lock also has a lock body and a closing hoop that is lockable in the lock body that can be unlocked by means of an electric motor, with the unlocking of the closing hoop requiring, in the above-described manner, a positive authentication of a mobile end device30after the actuation of an actuation element of the lock10. A third embodiment of a locking system in accordance with the invention is shown inFIG.4that differs from the first embodiment described with reference toFIG.1in that the lock10is not a hoop lock, but rather a battery compartment lock that is attached to a frame40of a bicycle42and that serves the securing of a traction battery44of the bicycle42. To this extent, this lock10does not have any closing hoop, but instead a latch, not shown in any more detail, for securing the traction battery44received in the battery compartment, said latch being movable into a release position by an electric motor of the lock to release the traction battery44as soon as a positive authentication of a mobile end device30has taken place after the actuation of an actuation element of the lock10in the above-described manner. It is understood that a bicycle42can also be equipped with both a frame lock10ofFIG.3and a battery compartment lock10ofFIG.4. It is advantageous in this case if both locks10can be unlocked using one and the same mobile end device30. It is, however, generally also conceivable to provide separate mobile end devices30for unlocking the frame lock10, on the one hand, and the battery compartment lock10, on the other hand. It is further understood that when the bicycle42is an e-bike, the battery compartment lock10and/or the frame lock10does/do not necessarily have to have their own energy store22, but can instead be connected to the traction battery44of the bicycle42for the energy supply. REFERENCE NUMERAL LIST 10lock12closing hoop14lock body16locking element18locking recess20unlocking motor22energy store24connector element26actuation element28authentication module29transmission/reception unit30mobile end device31transmission/reception unit32switch-on element34emergency energy store36connector element37slider38housing40frame42bicycle44traction battery | 7,850 |
11859412 | DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring toFIG.1, there is shown the improved calibratable high Gauss lock10comprising a Zamak metal conical ball cage50, a ball basket60made of polyacetal POM where the ball bearings150are mounted which are pushed upwards by the force of a non-ferrous spring40which can be made of phosphor bronze and pulled down when pulled by the ferro-magnetic material composed of the ball bearings150and the calibratable washer30that can be made of high grade low magnetic tolerance steel such as steel type S235JR or a similar material. The lock is depicted inside a specific EAS tag20having an EAS security element but may also fit inside another EAS tag or device which needs to be locked and/or unlocked. FIG.2shows a presently preferred embodiment of an EAS tag20comprised of a plastic pin110and a plastic body190of the tag containing the improved calibratable high Gauss lock10. The plastic pin110includes a plastic body112, a pin114and a plastic dome116. The pin114has a shoulder118connected to body112and a shank120. Plastic dome116may carry a pre-printed commercial message such as a logo or a QR code with no protective transparent window. The housing190includes the conical ball cage50, the ball basket60, the ball bearings150, the non-ferrous spring40, and the calibratable washer30as referred to inFIG.1. The housing body is preferably fully enclosed and includes a base192and a top194. Base192includes an upwardly extending annular wall196for connecting to and holding lock10. Top194includes a downwardly extending annular leg198for connecting to wall196, thereby holding lock10in place. The conical ball cage50may be made of a Zamak metal or a similar non-magnetic metal. The ball cage50has a conical shape with a top wall52, side wall54and bottom wall56. Side wall54is tapered on an inside surface to stop upward movement of ball basket60. The top wall52has an opening53for receiving the shank120of pin114and an opening57to engage the ball basket60, thereby retaining ball bearings150. The ball basket60may be made of POM or a similar plastic or other non-magnetic material. The ball basket is annular with a side wall62with a top wall64having a shoulder66and a bottom wall68. The top wall64has an opening65and bottom wall68has an opening69. Shoulder66fits in opening57and may move upward on sidewall54a certain distance such that ball bearings150engage pin shank120to secure the EAS tag to merchandise. In a preferred embodiment, there are four ball bearings150, one not being shown in the Figures based on the cross-sectional view. The ball bearings are made of a magnetic metal. It is understood that a different number of ball bearings may be used without departing from the scope of the invention. There is a resonant device140that receives and/or emits radio signals. The resonant device may include, but is not limited to, any of an EAS label; an antenna; or a security device or electronic label such as an RFID element/antenna for the purpose such as, but not limited to, one or multiple traceability, merchandising, marketing, pricing or inventory purposes. Referring toFIG.3, there is shown an exploded view of a high Gauss magnetic Detacher200such as described in U.S. Pat. No. 6,084,498 comprising a plastic housing210which may be made of ABS plastic, an annular neodymium high grade magnet220, a magnetic assembly of neodymium magnets230comprising at least two magnets, and a metallic base220which can be made of iron to contain the magnetic field. There is also shown the nesting area or spot240on the magnet assembly's surface where the EAS tags rest to be released. Referring toFIGS.4A and4B, there is shown inFIG.4Aa metal washer30used in the improved calibratable high Gauss lock as the calibrating element to interact with different Detachers that generate different Gauss values on their spot.FIG.4Bshows a cross-section of metal washer30taken along line A-A ofFIG.4A. In a preferred embodiment the metal washer is made of steel type S235JR. The thickness of the washer may be varied to calibrate the magnetic force needed to remove the body190from pin110by detacher200. FIG.5shows the EAS tag20ofFIG.2sitting on the nesting area240of a magnetic Detacher200with a Gauss value of about 17,000 Gauss on its nesting area240and about 10,000 Gauss at the height260where the ferro-magnetic parts of the improved calibratable high Gauss lock10are located: ball bearings150and the calibratable washer30which are about 11 mm from the spot240. The detacher200through the magnetic attraction to, the ball bearings150and washer30will cause the non-ferrous spring40to compress by pulling ball basket60downward thereby releasing ball bearings150from engagement with pin110and allowing the removal of pin110from body190. FIGS.6A-6Crepresent the same EAS tag20shown inFIG.5with the same new improved calibratable high Gauss lock10, the same ball bearings150, the same spring40and three different metal washers70,80and30wherein the thickness of washer70is thicker than washer80which is thicker than washer30to interact and release the pin110respectively with Gauss values of 5,000 by detacher201inFIG.6A; 10,000 by detacher202inFIG.6Band 17,000 Gauss by detacher200inFIG.6Con each Detacher's nesting area. More specifically, washer70has a thickness of 1 mm; washer80has a thickness of 0.85 mm; and washer30has a thickness of 0.5 mm. FIGS.7A and7Brepresent a front view of the same tag20ofFIG.5(except as noted below) on the nesting area of the same high Gauss lock Detacher200whereas the non-ferrous spring40of lock10retracts normally to release the pin110inFIG.7A.FIG.7Brepresents the same tag20ofFIGS.5and7A, except that the non-ferrous spring40has been replaced with a ferrous spring340that bends, thereby preventing the pin110from being released without moving the tag20in a back and forth motion350until the ferrous spring retracts properly. The exemplary embodiments herein disclosed are not intended to be exhaustive or to unnecessarily limit the scope of the invention. The exemplary embodiments were chosen and described in order to explain the principles of the present invention so that others skilled in the art may practice the invention. As will be apparent to one skilled in the art, various modifications can be made within the scope of the aforesaid description. For example, the shape of the ball cage50, ball basket60and calibratable metal washer may vary or the EAS security element may be in the plastic pin. Such modifications being within the ability of one skilled in the art form a part of the present invention and are embraced by the appended claims. | 6,649 |
11859413 | DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION In further development of the concept of providing security strips to laptop computers, reference is made to prior artFIGS.10and11which show a particular model of a laptop computer currently marketed by the Apple Corporation. Referring toFIG.10, the laptop computer200has a main body201that supports a keyboard202and has a hingedly attached display203. The thickness “t”204of the body201becomes progressively smaller (thinner) in a direction from the rear205to the front206of the body201. The laptop body201includes various input/output devices209. Prior artFIG.11shows the same laptop computer200, but also reveals that it has support cushions207and208on which the body201rests. These cushions207and208lift the laptop body201above a surface on which it rests. Referring toFIG.12, the novel security strip210of the present invention has a length dimension217, a width dimension215and a thickness213substantially so that the thickness213is a small fraction of the length and width dimensions of the security strip210. The security strip210also carries, adjacent its opposed ends, circular cutouts211and213, which as shown below, are intended to enable locating therein the cushions207and208of the laptop200. The screw holes214a,214b,214cand another one (not shown) by which the strip210can be attached to the bottom of the laptop200, enable firm attachment of the security strip210to the underside of the laptop200in a manner that makes it difficult to remove and walk off with the laptop computer. As further shown inFIG.12, at one distal end, a security slot220, similar to the one shown inFIG.2above, enables connecting a security lock and a cable thereto preventing theft of the laptop200. As further shown inFIG.13, the strip210is attached via screws to the underside of the laptop200with the cutouts211and213enabling fitting therein the cushions208at the left and right front side of the laptop. Thus, the strip has a thickness that is smaller than, but in any event, not larger than the thickness or extension of the cushions208. An additional security strip221may also be provided at the opposed side, as shown. FIG.14shows the strip but only with the security slots220and221on the left and right sides at the front end of the laptop200. Lastly, as indicated by the cut away lines231and232, instead of a strip that has a length that reaches across the laptop, either a left or a right portion thereof may be provided, or both but separated from each other at the mid-section of the laptop. Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims. | 2,896 |
11859414 | DETAILED DESCRIPTION Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. FIGS.1and2illustrate a security apparatus100embodying the invention. The security apparatus100is configured to engage a portable electronic device104(FIG.16) (e.g., a tablet computer, a laptop computer, a smartphone, an mp3 player, an eReader, etc.) to secure the portable electronic device104at a location. The illustrated security apparatus100includes a force-transmission member108(FIGS.3-7), a lock head112, and an actuator assembly116. The lock head112and the actuator assembly116are coupled to opposite ends of the force-transmission member108so that the actuator assembly116is located remote from the lock head112. This arrangement positions the actuator assembly116apart from the portable electronic device104so the actuator assembly116does not interfere with and/or block other ports, buttons, or sections of the portable electronic device104. As shown inFIGS.3-7, the illustrated force-transmission member108is a cable having a length, a first end120, and a second end124. The lock head112(FIGS.3-5) is coupled to the first end120of the cable108. The actuator assembly116(FIGS.6-7) is coupled to the second end124of the cable108. As used herein, “end” refers to the portion of the cable108that is received in and coupled to the lock head112or the actuator assembly116, and not necessarily to the absolute terminus of the cable108. Connecting the lock head112and the actuator assembly116to opposite ends of the cable108spaces the actuator assembly116a distance D (FIG.2) from the lock head112. The distance D is measured along the length of the cable108and is not necessarily the shortest distance between the lock head112and the actuator assembly116. In addition, the distance D is fixed in that even though the cable108may bend, the cable108does not compress. As such, the distance D between the lock head112and the actuator assembly116, when measured along the length of the cable108, remains constant. An outer sheath128surrounds the cable108to protect and strengthen the cable108. The outer sheath128maintains the lock head112at the distance D, along the length of the cable108, from the actuator assembly116. The cable108is movable relative to the outer sheath128to move and actuate the lock head112. In the illustrated embodiment, the cable108slides within the outer sheath128. The cable108and the outer sheath128are also flexible to allow the lock head112and the actuator assembly116to move relative to each other, yet still retain the distance D between the lock head112and the actuator assembly116. In other embodiments, the cable108and/or the outer sheath128may be rigid structures that do not bend or flex. In some embodiments, the distance D between the lock head112and the actuator assembly116is at least 8 cm. In other embodiments, the distance D may be longer or shorter (e.g., 5 cm, 10 cm, 1 m, etc.), depending on the desired application or use of the security apparatus100. As shown inFIGS.3-5, the lock head112is coupled to the first end120of the cable108. At least a portion of the lock head112is configured to be received in an opening or slot132formed in the portable electronic device104. When positioned within the slot132, the lock head112selectively engages the portable electronic device104to secure the security apparatus100to the device104. In particular, the lock head112is movable between a first, unlocked position (FIG.4) and a second, locked position (FIG.5). The illustrated lock head112includes a body136, an expandable portion140, a plunger144, and a biasing member148. A portion of the body136is removed inFIGS.3-5to help illustrate the internal components of the lock head112. The body136receives a portion of the outer sheath128that is adjacent the first end120of the cable108to fix the lock head112to the sheath128. In some embodiments, the outer sheath128may be clamped and/or glued within the body136. The body136also houses and supports the other components of the lock head112. The expandable portion140is coupled to and extends outwardly from the body136. In the illustrated embodiment, the expandable portion140extends axially from the body136and is generally aligned with a longitudinal axis of the cable108when the cable108is straightened. The illustrated expandable portion140includes two spaced apart latches152. The latches152, or tabs or fingers, are movable relative to the body136between the unlocked position (FIG.4) and the locked position (FIG.5). An elastomeric element156(e.g., an O-ring or rubber band) surrounds the latches152to help bias the latches152toward the unlocked position. The elastomeric element156also seals an end of the body136. When in the unlocked position, the latches152are positioned radially inward so that the latches152are spaced apart from and disengage the portable electronic device104. In this position, the lock head112can be inserted into and removed from the slot132in the device104. When in the locked position, the latches152are moved (e.g., pivoted) away from each other and radially outward relative to the body136. In this position, the latches152engage the portable electronic device104to secure the lock head112to the device104. In other embodiments, the expandable portion140may include other types or configuration of latches suitable for engaging the portable electronic device104. For example, in some embodiments, the expandable portion140may include latches that are at least partially composed of a resilient material so that the latches are naturally biased toward the unlocked position (e.g., toward each other). Additionally or alternatively, the expandable portion140may include three or more latches or only a single latch that engages the device104. The illustrated plunger144, or wedge, is positioned partially within the body136and between the latches152of the expandable portion140. In the illustrated embodiment, the plunger144includes a tapered or narrow portion160and a flared or wide portion164. The tapered portion160of the plunger144is coupled to the first end120of the cable108. The flared portion164of the plunger144is the distal, free end of the plunger144. In operation, the cable108pulls the plunger144in the direction of arrow A when actuated by the actuator assembly116to move the lock head112from the unlocked position to the locked position. When the lock head112is in the unlocked position (FIG.4), the tapered portion160of the plunger144is aligned with the latches152so that the latches152are biased radially inward by the elastomeric element156. When the lock head112is in the locked position (FIG.5), the flared portion164is aligned with and engages the latches152to push the latches152radially outward. The biasing member148is positioned within the body136and coupled to the plunger144. The biasing member148biases the plunger144toward the unlocked position (i.e., in the direction opposite the arrow A) so that the tapered portion160of the plunger144is aligned with the latches152. In the illustrated embodiment, the biasing member148is a coil spring that is wrapped around the first end120of the cable108. In other embodiments, other suitable biasing members may also or alternatively be employed. As shown inFIGS.6and7, the actuator assembly116is coupled to the second end124of the cable108. The actuator assembly116is operable to actuate (e.g., pull) the cable108to move the lock head112between the unlocked position and the locked position. The illustrated actuator assembly116includes a body168, a movable member172, a manual actuator176, and a lock mechanism180. A portion of the body168, or frame, is removed inFIGS.6and7to facilitate illustration of the internal components of the actuator assembly116. The body168receives a portion of the outer sheath128adjacent the second end124of the cable108to fix the actuator assembly116to the sheath128. In some embodiments, the outer sheath128may be clamped and/or glued within the body168. The body168houses and supports the other components of the actuator assembly116. The movable member172is positioned within the body168and coupled to the second end124of the cable108by a ferrule182. The ferrule182is secured to the cable108and abuts the movable member172such that movement of the member172also moves the ferrule182and the cable108. The illustrated movable member172is a ramp including a first inclined or ramped surface184that cooperates with the manual actuator176. As shown inFIGS.8A and8B, the movable member172also includes a projection188, or tooth, having an inclined or ramped surface192and a stop surface196that cooperate with the lock mechanism180. In the illustrated embodiment, the first ramped surface184is formed in an upper surface of the movable member172, and the second ramped surface192and the stop surface196are formed in a side of the movable member172. The movable member172is movable within the body168to selectively pull and release the cable108. When the movable member172pulls the cable108, the cable108in turn pulls the plunger144(FIGS.4and5) to move the lock head112to the locked position. When the movable member172releases the cable108, slack is created in the cable108so that a biasing member200biases the movable member172toward the lock head112. In the illustrated embodiment, the biasing member200is a coil spring that surrounds a portion of the cable108. In other embodiments, other suitable types of biasing members may also or alternatively be employed. Referring back toFIGS.6and7, the manual actuator176is supported by and extends out of the body168. In the illustrated embodiment, the actuator176is a push button that is depressible by a user to move the actuator176relative to the body168. In other embodiments, other suitable actuators (e.g., levers, dials, etc.) may also or alternatively be employed. The actuator176includes an inclined or ramped surface204that engages the first ramped surface184of the movable member172. The actuator176is movable between a first, extended position (FIGS.6and8A-8B) and a second, depressed position (FIGS.7and9A-10B). When in the first position, the actuator176is fully extended from the body168. In this position, the movable member172can move toward the lock head112under the force from the biasing member200, thereby releasing the cable108so that the lock head112is movable to the unlocked position. When in the second position, the actuator176is depressed relative to the body168. In this position, the movable member172is pushed away from the lock head112against the force from the biasing member200, thereby pulling the cable108to move the lock head112to the locked position. As shown inFIGS.8A,9A, and10A, the illustrated lock mechanism180includes a lock cylinder208, a lock member212, and a biasing member216. The lock cylinder208is positioned within the body168and is configured to receive a key. In the illustrated embodiment, the key is operable to selectively unlock the lock mechanism180and, thereby, selectively allow movement of the actuator176relative to the body168and the movable member172. In other embodiments, the key may be operable to both selectively lock and unlock the lock mechanism180. The lock member212, or toggle, is coupled to an end of the lock cylinder208for movement relative to the lock cylinder208. The illustrated lock member212includes a projection220extending toward and engaging the movable member172. The projection220includes an inclined or ramped surface224and a back surface228. The ramped surface224defines a recess232that is shaped and sized to receive the tooth188of the movable member172. The recess232divides the projection220into two lobes220A,220B (FIGS.8B,9B, and10B). The back surface228is formed on the second lobe220B. The lock member212is movable (e.g., rotatable) between a first position (FIGS.8A-8B and10A-10B), in which the projection220extends toward the movable member172, and a second position (FIGS.9A-9B), in which the projection220is pivoted away from the movable member172(e.g., downward in the figures). The biasing member216is coupled to the lock member212to bias the lock member212toward the first position. In the illustrated embodiment, the biasing member216is a torsion spring. In other embodiments, other suitable biasing members may also or alternatively be employed. FIGS.8A-10Billustrate operation of the actuator assembly116. Initially, when the security apparatus100is in the unlocked position (FIGS.8A-8B), the manual actuator176is in the extended position, the movable member172is pushed by the biasing member200toward the lock head112, and the lock member212extends toward the movable member172so that the recess232receives the tooth188. From this position, the manual actuator176can be depressed by a user to move the security apparatus100to the locked position. In particular, depressing the manual actuator176in the direction of arrow B causes the ramped surface204of the actuator176to push against the first ramped surface184of the movable member172. The movable member172is then pushed away from the lock head112. As the movable member172moves away from the lock head112, the second ramped surface192on the tooth188pushes against the ramped surface224of the lock member212, causing the lock member212to rotate in the direction of arrow C, as shown inFIGS.9A-9B. The lock member212continues to rotate until the projection220(more particularly, the second lobe220B) clears the apex of the tooth188. Once the projection220clears the tooth188, the lock member212is automatically rotated in the direction opposite arrow C under the force of the biasing member216to extend back toward the movable member172, as shown inFIGS.10A-B. In this position, the back surface228of the projection220engages the stop surface196of the tooth188to inhibit movement of the movable member172toward the lock head112. The lock mechanism180, thereby, holds the manual actuator176, the movable member172, and the lock head112in the locked position. To release the lock head112from the locked position, a suitable key is inserted into the lock cylinder208and turned to move (e.g., rotate) the projection220of the lock member212temporarily out of engagement with the movable member172. In particular, actuating the lock mechanism180with the key rotates the lock member212in the direction of arrow C (FIGS.8A and9A). As the lock member212rotates, the back surface228on the projection220slides along the stop surface196of the tooth188. Once the projection220clears the tooth188, the movable member172is movable back toward the lock head112under the force of the biasing member200. Moving the movable member172toward the lock head112releases the cable108so that the lock head112also moves to the unlocked position. In addition, moving the movable member172toward the lock head112raises the manual actuator176back to the extended position (i.e., in the direction opposite arrow B). The manual actuator176, the movable member172, and the lock head112are then held in the unlocked position until the actuator176is depressed again. In other embodiments, the cable108may be a different type of force-transmission member. For example, the force-transmission member108extending between the lock head112and the actuator assembly116may be a rigid structure, such as a rod. In this arrangement, the actuator assembly116may push the rigid force-transmission member (and, thereby, the plunger144) to move the security apparatus100to the released position. In addition, the actuator assembly116may pull the rigid force-transmission member (and, thereby, the plunger144) to move the security apparatus100to the locked position. With such an arrangement, the biasing members148,200may be omitted. Referring back toFIGS.1and2, the actuator assembly also includes a mount236extending from the body168. The mount236is configured to receive a security cable240(FIG.16). The security cable240is fixed within the mount236and secured to an immovable object (e.g., a desk, a table, a wall, etc.) to secure the security apparatus100, and thereby a connected portable electronic device, to the immovable object. The illustrated mount236includes a first portion244that is fixed to the body168and a second portion248that is pivotally coupled to the first portion244. The second portion248defines a bore252that receives the security cable240. The pivotal connection between the first and second portions244,248allows the security cable240to be oriented in different directions relative to the body168. In other embodiments, the actuator assembly116may be directly bolted, glued, or otherwise secured to an immovable object. In such embodiments, the mount236and the security cable240may be omitted. FIG.11illustrates the security apparatus100engaging the slot132in the portable electronic device104. The security apparatus100is designed to take up a minimal amount of space immediately adjacent the device104so that the apparatus100does not interfere with or block other portions of the device104. The illustrated locking head112of the security apparatus100has a length L, a width W, and a height H. In some embodiments, the length L is between about 15 mm and about 40 mm, the width W is between about 8 mm and about 15 mm, and the height H is between about 5 mm and about 11 mm. In the illustrated embodiment, the length L is about 28 mm, the width W is about 11.5 mm, and the height H is about 8 mm. The end profile of the locking head112(i.e., the end of the locking head112that faces the portable electronic device104), therefore, is relatively small compared to other locking heads on the market. In other embodiments, other suitable dimensions of the locking head112that take up a minimal amount of space immediately adjacent the slot132may also be possible. As shown inFIGS.12and13, the slot132in the portable electronic device104is dimensioned to receive the expandable portion140of the locking head112. The illustrated slot132has an opening width WO, a clearance width WC, a slot height HS, a wall thickness TW, and a clearance depth Dc. The opening width WOis the width of the slot132at the exterior surface of the portable electronic device104. The clearance width WCis the width of the slot132inside the device104to provide clearance for the expandable portion140to expand. The slot height HSis the height of the slot132at the exterior surface of the portable electronic device104. The wall thickness TWis the thickness of an exterior wall of the device104that defines the slot132and that is engaged by the expandable portion140of the locking head112. The clearance depth Dc is the depth or length of the slot132into the device104beyond the exterior wall. In some embodiments, the opening width WOis between about 6 mm and about 8 mm, the clearance width WCis at least about 9 mm, the slot height HSis between about 2 mm and about 4 mm, the wall thickness TWis between about 3 mm and about 5 mm, and the clearance depth Dc is at least about 4 mm. In such embodiments, the slot132has a total depth into the device104that is between about 7 mm and about 10 mm. In the illustrated embodiment, the opening width WOis about 7 mm, the slot height HSis about 3 mm, and the wall thickness TWis about 4 mm. In other embodiments, other suitable slot dimensions may also be possible. FIGS.14and15illustrate the security apparatus100with customizable housing assemblies256A-C,260A-C. The housing assemblies256A-C,260A-C are positioned over the actuator assembly116to provide different visual appearances and/or tactile properties to the apparatus100. For example, the housing assemblies256A-C,260A-C may be removable and interchangeable to provide different colors, as desired by a user. Additionally or alternatively, the housing assemblies256A-C,260A-C may include different indicia for various logos, brands, or other identifiers, as desired for particular applications. As shown inFIG.14, each of the illustrated housing assemblies256A-C includes two clamshell covers264A-C that surround an inner frame268of the actuator assembly116. The clamshell covers264A-C may be formed of, for example, a plastic material and may snap together to substantially cover the inner frame268. In contrast, the inner frame268of the actuator assembly116may be composed of, for example, die cast zinc or other relatively hard metallic materials. Together, the clamshell covers264A-C and the inner frame268form the body168of the actuator assembly116. As shown inFIG.15, each of the illustrated housing assemblies260A-C includes a rubber outer ring272A-C that surrounds the inner frame268of the actuator assembly116. The outer rings272A-C may be formed of an elastomeric material such that the rings272A-C can stretch and deform to substantially cover the inner frame268. The outer rings272A-C also provide a softer surface than the metallic inner frame268to absorb impacts in case the actuator assembly116is accidentally dropped and/or impacts another surface. Furthermore, the outer rings272A-C have higher coefficients of friction than the metallic inner frame268to inhibit the actuator assembly116from freely sliding along a surface. Together, the outer ring272A-C and the inner frame268form the body168of the actuator assembly116. In some embodiments, the clamshell covers264A-C and the rubber outer rings272A-C may be used in combination (e.g., one of the outer rings272A-C may surround one of the clamshell covers264A-C). In other embodiments, the clamshell covers264A-C and the outer rings272A-C may be omitted. FIG.16illustrates the security apparatus100in use with the portable electronic device104. The illustrated portable electronic device104is a laptop computer. The laptop computer104includes a housing276that is divided into a monitor portion280and a base portion284. The monitor and base portions280,284are pivotally coupled together. The monitor portion280supports a screen288. The base portion284supports input devices292(e.g., a keyboard and a touchpad). In the illustrated embodiment, the slot132is formed in the base portion284between two USB ports296. When the lock head112is inserted into the slot132and moved to the locked position, the security apparatus100is secured to the laptop computer104. The security apparatus100, in turn, is secured to an immovable object by the security cable240so that the laptop computer104is secured to the immovable object. In addition, the actuator assembly116is spaced apart or positioned away from the laptop computer104so that the actuator assembly116does not block or interfere with the USB ports296(or any other ports, buttons, connectors, etc.) on the base portion284. FIGS.17-19illustrate another security apparatus300. The security apparatus300is similar to the security apparatus100discussed above with reference toFIGS.1-16. Reference is made to the description of the security apparatus100above for details of the structure and operation of the security apparatus300not included below. The illustrated security apparatus300includes a cable304, an outer sheath308, a lock head312, and an actuator assembly316. As shown inFIGS.18and19, the lock head312is coupled to a first end320of the cable304. The illustrated lock head312includes a body324, an expandable portion328, a plunger332, and a biasing member336. In the illustrated embodiment, the expandable portion328includes two latches340that are integrally formed with the body324. In other embodiments, the latches340may be discrete elements that are separate from the body324. The illustrated plunger332is coupled to the cable304by a bushing344. Similar to the lock head112described above, when the plunger332is actuated (e.g., pulled by the cable304), the latches340move radially outward. As the latches340move (e.g., flex) outwardly, the latches340engage a portable electronic device to secure the lock head312to the device. When the cable304is released, the biasing member336returns the plunger332to an extended position (FIG.18) so that the latches340can move radially inward. As the latches340move inwardly, the latches340disengage the portable electronic device so that the lock head312is unsecured from the device. The actuator assembly316is coupled to a second end348of the cable304. The actuator assembly316is operable to actuate (e.g., pull) the cable304and, thereby, the plunger332in the lock head312. The illustrated actuator assembly316includes a body352, a movable member356, a biasing member360, a lever364, and a lock mechanism368. The body352is fixed to the outer sheath308adjacent the second end348of the cable304. The body352houses and supports the other components of the actuator assembly. The body352also defines a pair of openings372for receiving a security cable (e.g., the security cable240shown inFIG.16). The security cable can be threaded through the openings372and secured to an immovable object to secure the security apparatus300, and thereby the portable electronic device, to the immovable object. The movable member356is positioned within the body352and coupled to the second end348of the cable304. The illustrated movable member356is a lock block that is movable within the body352to pull and release the cable304. The biasing member360biases the movable member356toward the lock head312to release the cable304. In the illustrated embodiment, the biasing member360is a coil spring that is wrapped around the cable304. In other embodiments, other suitable biasing members may also or alternatively be employed. The lever364is positioned within the body352and coupled to the lock mechanism368. The lever364is operable to pivot relative to the body352to move the movable member356. The illustrated lever364pivots between a first position (FIG.18), in which the movable member356is allowed to move toward the lock head312under the force from the biasing member360, and a second position (FIG.19), in which the lever364pushes the movable member356away from the lock head312against the biasing member360. The lever364can be secured in either position by the lock mechanism368. As shown inFIG.17, the illustrated lock mechanism368is a cylinder lock that extends generally perpendicularly from the body352(relative to a longitudinal axis of the cable304when the cable304extends straight from the actuator assembly316). The lock mechanism368is configured to receive a key376to selectively lock and unlock the lock mechanism368. In this embodiment, the key376functions as a manual actuator. When the lock mechanism368is unlocked (e.g., when the key376is turned in a first direction), the lever364is pivoted to the first position (FIG.18) so that the movable member356can slide toward the lock head312under the force of the biasing member360. In this position, the movable member356releases the cable304to allow the expandable portion328to relax radially inward. When the lock mechanism368is locked (e.g., when the key376is turned in a second direction), the lever364is pivoted to the second position (FIG.19) so that the lever364pushes the movable member356away from the lock head312against the force of the biasing member360. In this position, the movable member356pulls the cable304to move the plunger332and expand the expandable portion328. FIGS.20and21illustrate security apparatuses400,500that are similar to the security apparatus300ofFIGS.17-19, and like parts have been given the same reference numbers. The actuator assembly316of the security apparatus400shown inFIG.20, however, includes a body452that is generally circular in cross-section. The body452defines an opening472for receiving a security cable (e.g., the security cable240shown inFIG.16). The actuator assembly316of the security apparatus500shown inFIG.21includes a body552having flattened, opposing sides556such that the body552is oblong in cross-section. The body552also defines an opening572for receiving a security cable (e.g., the security cable240shown inFIG.16). FIGS.22-26illustrate another security apparatus600. The security apparatus600is similar to the security apparatus100discussed above with reference toFIGS.1-16. Reference is made to the description of the security apparatus100above for details of the structure and operation of the security apparatus600not included below. The illustrated security apparatus600includes a cable604, an outer sheath608, a lock head612, and an actuator assembly616. The cable604, the outer sheath608, and the lock head612are substantially the same as the cable108, the outer sheath128, and the lock head112discussed above. As shown inFIGS.23-26, the actuator assembly616is coupled to an end620of the cable604opposite from the lock head612. The actuator assembly616is operable to actuate (e.g., pull) the cable604to move the lock head612between an unlocked position (FIG.23) and a locked position (FIG.25). The illustrated actuator assembly616includes a body624, a movable member628, two biasing members632,636, and a lock mechanism640. The body624is fixed to the outer sheath608adjacent the end620of the cable604. The body624houses and supports the other components of the actuator assembly616. The body624also defines a pair of openings644for receiving a security cable (e.g., the security cable240shown inFIG.16) that secures the actuator assembly616to an immovable object. The movable member628is positioned within the body624and coupled to the end620of the cable604. The illustrated movable member628is a cam follower that is movable within the body624to pull and release the cable604. The biasing members632,636bias the movable member628toward the lock head612to release the cable604. In the illustrated embodiment, the biasing members632,636are coil springs that are wrapped around the cable604. The first biasing member632extends between an inner surface of the body624and the movable member628. The second biasing member636extends between a sleeve648secured to the cable604and the movable member628. In other embodiments, other suitable biasing members may also or alternatively be employed. In the illustrated embodiment, the lock mechanism640is a cylinder lock that extends generally parallel to a longitudinal axis of the cable604(when the cable604extends straight from the actuator assembly616). The lock mechanism640includes a cam652that engages the movable member628. The lock mechanism640is also configured to receive a key to selectively rotate the lock mechanism640and, more particular, the cam652. In this embodiment, the key functions as a manual actuator. When the lock mechanism640is rotated by the key to the unlocked position (FIGS.23and24), the cam652allows the movable member628to be pushed by the biasing members632,636toward the lock head616. In this position, the cable604is released so that the lock head612is in the unlocked position. When the lock mechanism640is rotated by the key to the locked position (FIGS.25and26), the cam652pushes the movable member628against the force of the biasing members632,636. In this position, the cable604is pulled by the movable member628to move the lock head612to the locked position. FIG.27illustrates a security apparatus700that is similar to the security apparatus600shown inFIGS.22-26, and like parts have been given the same reference numbers. The actuator assembly616of the security apparatus700shown inFIG.27, however, has a generally cylindrical body724, rather than the mailbox-shaped body624shown inFIG.22. In addition, the cylindrical body724includes a rippled outer surface728to facilitate handling the actuator assembly616. The cylindrical body724also includes a boss732extending radially from a mid portion of the body724. The boss732is configured to receive a portion of a security cable to connect the actuator assembly616to an immovable object. FIGS.28-30illustrate another security apparatus800. The security apparatus800is similar to the security apparatus100discussed above with reference toFIGS.1-16. Reference is made to the description of the security apparatus100above for details of the structure and operation of the security apparatus800not included below. The illustrated security apparatus800includes a cable804, an outer sheath808, a lock head812, and an actuator assembly816. As shown inFIG.29, the lock head812includes an expandable portion820and a plunger824. The expandable portion820is fixed to the outer sheath808. In the illustrated embodiment, the expandable portion820includes four collet tabs828. The collet tabs828are movable (e.g., flexible) radially outward and away from each from an unlocked position to a locked position. When the collet tabs828move radially outward to the locked position, the tabs828can engage a portable electronic device to secure the lock head812to the device. When the collet tabs828move radially inward to the unlocked position, the tabs828disengage the portable electronic device such that the lock head812can be removed from the device. The illustrated collet tabs828are configured to fit within and engage a circular opening in a portable electronic device, rather than the rectangular slot or opening132shown inFIGS.11-13and16. The plunger824is positioned within the expandable portion820and coupled to the cable804. The illustrated plunger824is generally conical in shape with a flared (i.e., larger diameter), distal free end832. Similar to the plunger144discussed above, the illustrated plunger824is movable with the cable804relative to the expandable portion820to push the collet tabs828radially outward and into the locked position. As shown inFIG.30, the actuator assembly816is coupled to an end836of the cable804opposite from the lock head812. The actuator assembly816is operable to actuate (e.g., pull) the cable804to move the lock head812between the unlocked position and the locked position. The illustrated actuator assembly816includes a body840, a movable member844, and a lock mechanism848. The body840is fixed to the outer sheath808adjacent the end836of the cable804. The body840houses and supports the other components of the actuator assembly816. The movable member844extends from the lock mechanism848and is coupled to the end836of the cable804. The illustrated movable member844is a lever that is pivoted by the lock mechanism848to push and pull the cable804toward and away from the lock head812. When the lever844is pivoted to pull the cable804away from the lock head812, the cable804pulls the plunger824to expand the collet tabs828. When the lever844is pivoted to push or release the cable804, the cable804allows the flared end832of the plunger824to slide axially out of the expandable portion820so that the collet tabs828can relax radially inward. In some embodiments, a biasing member may be coupled to the plunger832and/or the movable member844to bias the security apparatus800to the unlocked position. In the illustrated embodiment, the lock mechanism848is a cylinder lock supported by the body840. The lock mechanism848is directly coupled to the movable member844to pivot the movable member844. The lock mechanism848is also configured to receive a key to selectively rotate the lock mechanism848. In this embodiment, the key functions as a manual actuator. When the lock mechanism848is rotated by the key to the unlocked position, the lever844pushes the cable804. In this position, the cable804is released so that the lock head812is moved to the unlocked position. When the lock mechanism848is rotated by the key to the locked position, the lever844pulls the cable804. In this position, the cable804is tensioned so that the lock head812is moved to the locked position. FIGS.31-34illustrate another security apparatus900. The security apparatus900is similar to the security apparatus100discussed above with reference toFIGS.1-16. Reference is made to the description of the security apparatus100above for details of the structure and operation of the security apparatus900not included below. The illustrated security apparatus900includes a cable904, an outer sheath908, a lock head912, and an actuator assembly916. The cable904, the outer sheath908, and the lock head912are substantially the same as the cable304, the outer sheath308, and the lock head312shown inFIGS.17-19. The illustrated actuator assembly916includes a body920and a manual actuator924. Unlike the previously-described versions of security apparatuses, the actuator assembly916does not include a lock mechanism. The manual actuator924is pivotally coupled to the body920. In the illustrated embodiment, the manual actuator924includes a handle928and a flange932. The handle928is configured to be grasped by a user to pivot the actuator924. The flange932is secured to an end936of the cable904to selectively move the cable904. When the actuator924is pivoted to an unlocked position (FIGS.31and32), the flange932is moved flush with a rear surface940of the body924. In addition, the handle928is pivoted at least slightly away from an upper surface944of the body920. In this position, the flange932pushes or releases the cable904so that the lock head912moves to the unlocked position. When the actuator924is pivoted to the locked position (FIGS.33and34), the flange932is moved away from the rear surface940of the body920. In addition, the handle928is pivoted to lie flat on the upper surface944of the body920. In this position, the flange932pulls the cable904so that the lock head912moves to the locked position. In some embodiments, the manual actuator924may be biased to either the unlocked position or the locked position. For example, the actuator924may be biased by a biasing member (e.g., a torsion spring) toward the unlocked position. In such embodiments, the body920, the handle928, and/or the flange932may include a lock, latch, detent, magnet, or other securement mechanism to hold the actuator924in the locked position. Alternatively, the actuator924may be biased by a biasing member toward the locked position. In such embodiments, a user may temporarily actuate the actuator924to the unlocked position, connect the lock head912to a portable electronic device while the actuator is actuated924, and then release the actuator924to secure the security apparatus900to the device. In other embodiments, the manual actuator924may be configured as an over-center latch that moves to either the unlocked position or the unlocked position, but does not remain in any intermediate positions. FIG.35illustrates a system1000for securing or locking a plurality of portable electronic devices1004in place. In the illustrated embodiment, the portable electronic devices1004are tablet computers. The illustrated system1000includes a plurality of the security apparatuses900and an enclosure1008. Each security apparatus900is connected to one of the portable electronic devices1004. Although the illustrated security apparatuses900do not include lock mechanisms, in other embodiments the apparatuses900may also include individual lock mechanisms. More particularly, any of the security apparatuses described herein may be used in place of the security apparatuses900shown in the figure. The illustrated enclosure1008is a cabinet including an outer wall1012. The outer wall1012defines an interior volume1016of the cabinet1008and has two doors1020that provide selective access to the interior volume1016. A relatively small hole or opening1024is formed in the outer wall1012and in communication with the interior volume1016. The cables and the outer sheaths908of the security apparatuses900extend through the opening1024such that the lock heads912(and the attached portable electronic devices1004) are positioned and accessible from outside of the cabinet1008, but the actuator assemblies916are positioned inside the cabinet908. The hole1024is sized to be smaller than the actuator assemblies916so that the actuator assemblies916cannot be pulled out of the cabinet1008through the hole1024. The cabinet1008encloses the actuator assemblies916to inhibit unauthorized users from accessing the actuator assemblies916and, thereby, releasing (i.e., unlocking) the portable electronic devices1004. The cabinet1008itself can be locked and require a key, combination, passcode, biometric identifier, wireless signal (e.g., RFID or Bluetooth signal), or the like to be unlocked. In other embodiments, other suitable types of enclosures may be used to store and secure the actuator assemblies916of the security apparatuses900in a remote location. FIG.36illustrates another security apparatus1100. The security apparatus1100is similar to the security apparatus100discussed above with reference toFIGS.1-16. Reference is made to the description of the security apparatus100above for details of the structure and operation of the security apparatus1100not included below. The illustrated security apparatus1100includes a cable, an outer sheath1108, a lock head1112, and an actuator assembly1116. The cable, the outer sheath1108, and the actuator assembly1116are substantially the same as the cable108, the outer sheath128, and the actuator assembly116shown inFIGS.1-16. The lock head1112is coupled to an end of the cable opposite the actuator assembly1116. The lock head1112includes a body1120having an opening1124. The opening1124is configured to receive a portion of a portable electronic device1128to secure the lock head1112to the device1128. In the illustrated embodiment, the opening1124receives a boss1132extending from a housing1136of the portable electronic device1128. Gate structures (not shown) positioned within the body1120selectively engage the boss1132when the boss1132is inserted into the opening1128. The illustrated lock head1112and boss1132may be similar to the locking heads and attachment devices disclosed in U.S. Pat. No. 7,997,106, issued Aug. 16, 2011, the entire contents of which are hereby incorporated by reference. The gate structures of the illustrated lock head1112are coupled to the cable such that actuating the actuator assembly1116moves the gate structures into and out of engagement with the boss1132. When the gate structures engage the boss1132, the lock head1112is secured to the portable electronic device1128. When the gate structures disengage the boss1132, the lock head1112is removable from the portable electronic device1128. FIGS.37and38illustrate another security apparatus1200. The security apparatus1200is similar to the security apparatus100discussed above with reference toFIGS.1-16. Reference is made to the description of the security apparatus100above for details of the structure and operation of the security apparatus1200not included below. The illustrated security apparatus1200includes a cable, an outer sheath1208, a lock head1212, and an actuator assembly1216. The cable, the outer sheath1208, and the actuator assembly1216are substantially the same as the cable108, the outer sheath128, and the actuator assembly116shown inFIGS.1-16. The illustrated lock head1212includes a body1220and two wedges1224,1228. The body1220is secured to an end of the cable opposite from the actuator assembly1216. The first wedge1224is a stationary wedge. The stationary wedge1224extends axially from an end1232of the body1220. The second wedge1228is a movable wedge. The movable wedge1228also extends axially from the end1232of the body1220and is coupled to the cable to move with the cable. When the movable wedge1228is in an unlocked position (FIG.37), the wedge1228is slid into the body. In this position, the wedges1224,1228can be inserted into or removed from a slot in a portable electronic device. When the movable wedge1228is in a locked position (FIG.38), the wedge1228is slid out of the body. In this position, the wedges1224,1228engage the portable electronic device to secure the lock head1212to the device. In the illustrated embodiment, the actuator assembly1216and the cable are reconfigured compared to previous versions of security apparatuses so that the cable is pushed to move the movable wedge1228to the locked position and is released to move the movable wedge1228to the unlocked position. FIG.39illustrates another security apparatus1300. The security apparatus1300is similar to the security apparatus100discussed above with reference toFIGS.1-16. Reference is made to the description of the security apparatus100above for details of the structure and operation of the security apparatus1300not included below. The illustrated security apparatus1300includes a cable, an outer sheath1308, a lock head1312, and an actuator assembly1316. The cable, the outer sheath1308, and the lock head1312are substantially the same as the cable108, the outer sheath128, and the lock head112shown inFIGS.1-16. The illustrated actuator assembly1316includes a body1320, a manual actuator1324, and a lock mechanism1328. The manual actuator1324is supported by and extends from the body1320. In the illustrated embodiment, the manual actuator1324is a push button. The lock mechanism1328is also supported by the body1320. In the illustrated embodiment, the lock mechanism1328includes a combination lock1332having four rotatable dials1336. Each dial1336includes a series of numbers (e.g., 0 to 9) formed on the outer surface of the dial1336. The dials1336may be rotated to input a proper combination into the lock mechanism1328, thereby unlocking the lock mechanism1328. When the correct combination is entered, the lock mechanism1328may function in a similar manner as the lock mechanism180shown inFIGS.8A-10Bto unlock the lock head1312. In the illustrated embodiment, the dials1336rotate about an axis that is generally parallel to the longitudinal axis of the cable (when the cable is straightened), providing a generally in-line configuration for the lock mechanism1328. FIGS.40-42illustrate another security apparatus1400. The security apparatus1400is similar to the security apparatus100discussed above with reference toFIGS.1-16. Reference is made to the description of the security apparatus100above for details of the structure and operation of the security apparatus1400not included below. The illustrated security apparatus1400includes a cable, an outer sheath1408, a lock head1412, and an actuator assembly1416. The cable, the outer sheath1408, and the actuator assembly1416are substantially the same as the cable108, the outer sheath128, and the actuator assembly116shown inFIGS.1-16. The lock head1412is coupled to an end of the cable opposite from the actuator assembly1416. The illustrated lock head includes a body1420, an expandable portion1424, and a plunger1428. In the illustrated embodiment, the expandable portion1424includes four latches1432, or fingers, that are configured to fit within a square-shaped opening1436in a portable electronic device1440.FIG.41illustrates the latches1432in an unlocked position. In this position, the expandable portion1424can be inserted into and removed from the opening1436.FIG.42illustrates the latches1432in a locked position. In this position, the expandable portion1424engages the portable electronic device1440to secure the lock head1412to the device1440. FIGS.43-45illustrate another security apparatus1500. The security apparatus1500is similar to the security apparatus100discussed above with reference toFIGS.1-16. Reference is made to the description of the security apparatus100above for details of the structure and operation of the security apparatus1500not included below. The illustrated security apparatus1500includes a cable, an outer sheath1508, a lock head1512, and an actuator assembly1516. The cable, the outer sheath1508, and the actuator assembly1516are substantially the same as the cable108, the outer sheath128, and the actuator assembly116shown inFIGS.1-16. The lock head1512is coupled to an end of the cable opposite from the actuator assembly1516. The illustrated lock head1512includes a body1520, an expandable portion1524, and a plunger1528. In the illustrated embodiment, the expandable portion1524includes three latches1532, or fingers, that are configured to fit within a triangular-shaped opening1536in a portable electronic device1540.FIG.44illustrates the latches1532in an unlocked position. In this position, the expandable portion1524can be inserted into and removed from the opening1536.FIG.45illustrates the latches1532in a locked position. In this position, the expandable portion1524engages the portable electronic device1540to secure the lock head1512to the device1540. FIGS.46-48illustrate another security apparatus1600. The security apparatus1600is similar to the security apparatus100discussed above with reference toFIGS.1-16. Reference is made to the description of the security apparatus100above for details of the structure and operation of the security apparatus1600not included below. The illustrated security apparatus1600includes a cable, an outer sheath1608, a lock head1612, and an actuator assembly1616. The cable, the outer sheath1608, and the actuator assembly1616are substantially the same as the cable108, the outer sheath128, and the actuator assembly116shown inFIGS.1-16. The lock head1612is coupled to an end of the cable opposite from the actuator assembly1616. The illustrated lock head1612includes a body1620, an expandable portion1624, and a plunger1628. In the illustrated embodiment, the expandable portion1624includes four latches1632, or fingers, that are configured to fit within a circular-shaped opening1636in a portable electronic device1640.FIG.47illustrates the latches1632in an unlocked position. In this position, the expandable portion1624can be inserted into and removed from the opening1636.FIG.48illustrates the latches1632in a locked position. In this position, the expandable portion1624engages the portable electronic device1640to secure the lock head1612to the device1640. FIG.49illustrates another security apparatus1700. The security apparatus1700is similar to the security apparatus100discussed above with reference toFIGS.1-16. Reference is made to the description of the security apparatus100above for details of the structure and operation of the security apparatus1700not included below. The illustrated security apparatus1700includes a cable, an outer sheath1708, a lock head1712, and an actuator assembly1716. The cable, the outer sheath1708, and the actuator assembly1716are substantially the same as the cable108, the outer sheath128, and the actuator assembly116shown inFIGS.1-16. The lock head1712is coupled to an end of the cable opposite from the actuator assembly1716. The illustrated lock head1712includes a body1720and an expandable portion1724. In the illustrated embodiment, the expandable portion1724is a scissor-type mechanism. The scissor-type mechanism1724is configured to fit within a slot in a portable electronic device. In particular, the scissor-type mechanism includes two latches1728, or fingers, that are pivotally coupled to each other. When the actuator assembly1716is actuated to pull the cable, the cable causes the latches1728to pivot radially outward. As the latches1728pivot outwardly, the latches1728engage the portable electronic device to secure the lock head1712to the device. FIG.50illustrates a security apparatus1800that is similar to the security apparatus1700shown inFIG.49, and like parts have been given the same reference numbers. The lock head1712of the security apparatus1800ofFIG.50, however, includes a relatively larger scissor-type mechanism1824(e.g., larger latches or fingers1828) that are operable to engage a relatively larger slot in a portable electronic device. FIG.51illustrates another security apparatus1900. The security apparatus1900is similar to the security apparatus100discussed above with reference toFIGS.1-16and to the security apparatus1300discussed above with reference toFIG.39. Reference is made to the description of the security apparatuses100,1300above for details of the structure and operation of the security apparatus1900not included below. The illustrated security apparatus1900includes a cable, an outer sheath1908, a lock head1912, and an actuator assembly1916. The cable, the outer sheath1908, and the lock head1912are substantially the same as the cable108, the outer sheath128, and the lock head112shown inFIGS.1-16. The illustrated actuator assembly1916includes a body1920, a manual actuator1924, and a lock mechanism1928. The manual actuator1924is supported by the body1920. In the illustrated embodiment, the manual actuator1924is a slidable lever or switch positioned on an outer surface of the body1920. The lock mechanism1928is also supported by the body1920. Similar to the lock mechanism1328(FIG.39) discussed above, the lock mechanism1928includes a combination lock1932having four rotatable dials1936. The dials1936are rotatable to input a proper combination into the lock mechanism1928, thereby unlocking the lock mechanism1928. Unlike the dials1336discussed above, however, the illustrated dials1936rotate about an axis that is perpendicular to the longitudinal axis of the cable (when the cable is straightened) so that the lock mechanism1928extends outwardly from the remainder of the security apparatus1900. FIG.52illustrates another security apparatus2000. The security apparatus2000is similar to the security apparatus100discussed above with reference toFIGS.1-16. Reference is made to the description of the security apparatus100above for details of the structure and operation of the security apparatus2000not included below. The illustrated security apparatus2000includes a cable, an outer sheath2008, a lock head2012, and an actuator assembly2016. The cable, the outer sheath2008, and the lock head2012are substantially the same as the cable108, the outer sheath128, and the lock head112shown inFIGS.1-16. The illustrated actuator assembly2016includes a body2020, a manual actuator2024, and a lock mechanism2028. The manual actuator2024extends from and is supported by the body2020. Unlike the push button actuator176shown inFIGS.1and2, the illustrated manual actuator2024is a pivotable lever. The lock mechanism2028is also supported by the body2020. Similar to the lock mechanism180shown inFIGS.6-10B, the lock mechanism2028can secure the actuator2024in a depressed position. The illustrated security apparatuses allow the lock heads to be located remotely from the actuator assemblies (including the relatively bulky lock mechanisms) to reduce the possibility of blocking ports, buttons, or other sections of portable electronic devices. The lock heads only require minimum space on a device and can interface with devices less than 10 mm in height. In some embodiments, the lock heads can have dimensions between about 4 mm by 8 mm and about 9 mm by 12 mm. In addition, the security apparatuses are configured to withstand a minimum of axial pull forces of 150 lbf and side pull forces of 35 lbf. The security apparatuses described above thereby provide smaller attachments that interface with portable electronic devices, yet are still able to withstand substantial forces to secure the devices in place. Various features and advantages of the invention are set forth in the following claims. | 55,345 |
11859415 | The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. DETAILED DESCRIPTION The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. FIG.1illustrates a door handle assembly1which is mounted on a door2of a motor vehicle comprising a handle4represented in the open position. The door handle assembly1comprises a base3intended to be fastened on the door2. The handle4is linked to the base3via a hinge5at a first end6of the handle4and via an arm7slidably mounted in a housing8of the base3at a second end9of the handle4. The hinge5comprises a pivot arm22which is in rotation about an axis of rotation23. The pivot arm22has a first end linked to the base3via the axis of rotation23and a second end linked to the handle4. The handle4extends according to a longitudinal direction A′. The base3extends according to a longitudinal direction A which is parallel to the door2when the door handle assembly1is mounted thereon. When the handle4is in the rest position, the longitudinal direction A′ of the handle4is substantially (approximately) parallel to the longitudinal direction A of the door2. The handle4is movable in rotation relative to the base3between a rest position in which it is positioned substantially parallel to the base3, the arm7being inserted into the housing8, and an open position of the door2in which it is inclined relative to the base3, the arm7being partially outside the housing8, as illustrated inFIG.1. The longitudinal direction A′ of the handle4is then inclined relative to the longitudinal direction A of the door2. The handle4may be integral or comprise a handle body on which is fastened a cover or a gripping sleeve also having an aesthetic function. The arm7comprises a hook10at one of its ends11. The door handle assembly1comprises an actuation device12housed in the base3and which is intended to be linked to a mechanism for opening the door2(not represented). As illustrated inFIGS.2to5, the actuation device12comprises a first lever13engaging the hook10. The first lever13is mounted movable in rotation about an axis of rotation24in the housing8of the base3between a retracted position when the handle4is in the rest position and a deployed position when the handle4is in the open position. The actuation of the handle4causes the sliding of the hook10of the arm7of the handle4along a sliding axis Y and consequently the rotation of the first lever13of the actuation device12and toward the outside of the base3(direction opposite to the base3). This causes the actuation of the door2opening mechanism to open the door2. The sliding axis Y corresponds to the pathway followed by the arm7of the handle4. The actuation device12comprises a return spring15exerting a return force on the first lever13in order to bring it back toward its retracted position (initial position). The base3comprises an outer face26and an opposite inner face27. The handle4is positioned on the side the outer face26of the base3. The actuation device12comprises a second lever25positioned on the side the inner face27of the base3. The second lever25is accessible to a user from the inside of the vehicle in order to open the door2. The door2comprises a lock (not represented) mounted on the door2and positioned below the handle4. According to the present disclosure, the door handle assembly1comprises a blocking device14movably mounted on the base3between an unlocked position in which it does not cooperate with the actuation device12, as represented inFIGS.5to9, and a locked position, when the handle4is in the open position, as represented inFIGS.3,4,10and11. The displacement of the blocking device14toward its locked position causes a displacement of the actuation device12toward a mounting/dismounting position of the handle4in which the first lever13of the actuation device12is shifted relative to the sliding axis Y of the arm7of the handle4. The actuation device12is blocked in this position, so as to enable the arm7of the handle4to freely slide within the housing8of the base3along the sliding axis Y for its mounting in the base3or its dismounting from the base3. The first lever13of the actuation device12then does no longer hinder the passage of the arm7of the handle4in the housing8of the base3. The handle4can be freely mounted on or dismounted from the base3. The actuation device12is movable in rotation about an axis of rotation24between the rest position and the open position of the door2. The actuation device12may be assimilated to a cam with an axis of rotation24shifted relative to the sliding axis Y. Indeed, when a user pulls on the handle4toward the outside of the door2, the arm7of the handle4slides within the housing8of the base3along the sliding axis Y toward the outside of the door2until being partially outside the housing8, as illustrated inFIG.2. Since the first lever13of the actuation device12is engages the hook10of the arm7of the handle4, the latter performs a rotational movement about the axis of rotation24toward the outside of the door2toward the outer face26of the base3, thereby actuating an opening device to open the door2. The second lever25of the actuation device12performs the same rotational movement as the first lever13in order to be a little farther from the base3. The actuation device12is also movable in translation in the housing8of the base3along an axial direction X between an aligned position in which the first lever of the actuation device12is aligned with the sliding axis Y of the arm7of the handle4and a shifted position in which the first lever13of the actuation device12is shifted relative to the sliding axis Y. More specifically, the actuation device12is movable in translation after its rotation from its retracted position toward its deployed position, when the handle4is brought toward its open position. The blocking device14exerts a force against the actuation device12along the axial direction X and a direction opposite to that of the blocking device14in order to shift it relative to the sliding axis Y. The housing8has a dimension adapted to enable the translational movability of the actuation device12. The blocking device14exerts a force against the actuation device12along the axial direction X in order to block its axial movement in this direction and also in order to block its rotation, since the return spring15tends to bring the first lever13back toward its retracted position. The blocking device14comprises a rod16movable in translation relative to the base3between an unlocking position in which the rod16is disconnected from the actuation device12, as illustrated inFIGS.5to9, and a locking position in which the rod16exerts a pressure against the actuation device12in order to hold it shifted relative to the sliding axis Y, as represented inFIGS.3,4,10and11. The return spring15creates a tension along the axis Y when the rod16is pushing the first lever13. The rod16is movably mounted on the base3. The rod16has a latch function and exerts a force opposing that of the return spring15. The rod16extends longitudinally along the axial direction X which is substantially perpendicular to the sliding axis Y in this example. The axial direction X may be not perpendicular to the sliding axis Y. The rod16is movable in translation along the axial direction X and in rotation about an axis of rotation19extending along the axial direction X. The rod16is housed and held in two orifices28provided in the base3. The rod16comprises a lug30cooperating with two blocking devices31a,31bformed on the base3to block the translation of the rod16in the locking and unlocking position. The lug30protrudes radially on the surface of the rod16. A first blocking device31aallows blocking the lug30in the locking position (FIG.10). A second blocking device31ballows blocking the lug30in the unlocking position (FIG.8). The blocking devices31a,31bcomprise, in one form, two fastening elements32,34, also known as fasteners, disposed on either side of a slot33, as represented inFIG.10. The blocking devices31a,31bare distant from each other. The lug30is introduced or clipped into the slot33so as to be blocked. One of the fastening elements34has a surface35inclined toward the slot33in order to facilitate the insertion or the clipping of the lug30. The rod16comprises a first thread (not represented) cooperating with a second thread (not represented) provided in a threaded orifice29of the base3in order to screw or unscrew the rod16. The rod16slides in translation and in rotation through these orifices28,29. The rod16comprises an end lug17cooperating with a stop18formed on the base3in order to block the travel of the rod16when it is displaced toward its unlocking position. The end lug17protrudes on and around the outer surface of the rod16. When the rod16is completely unscrewed to its unlocking position, as represented inFIG.8, the end lug17of the rod16abuts against the stop18of the base3in order to stop the travel of the rod16. In this example, the stop18of the base3is formed by the walls delimiting an orifice28receiving the rod16. Conversely, when the rod16is completely screwed to the locking position, as represented inFIG.10, the lug30of the rod16is inserted or clipped into the slot33of the first blocking device31ain order to block the rod16in this position. The present disclosure also concerns a method for mounting and dismounting a door handle assembly1, as previously described, on a door2of a motor vehicle. This method comprises a step of positioning the actuation device12in the open position of the door2in order to bring the first lever13of the actuation device12in the deployed position, as represented inFIGS.1,2and7. This step is achieved by the actuation of the handle4for example by a user who pulls thereon. Alternatively, this step may be achieved by a user who pulls on the second lever25of the actuation device12. Conversely,FIGS.5,6,8and9show the actuation device12in the closed position of the door or rest position. The first lever13of the actuation device12is engaging the hook10of the arm7of the handle4. The first lever13is also in the retracted position (low position according to the planes ofFIG.5). During the step of positioning the actuation device12in the open position of the door2, the first lever13performs a rotational movement about an axis of rotation24extending along the axial direction X. Afterwards, the method comprises a step of shifting the first lever13of the actuation device12relative to the sliding axis Y of the arm7of the handle4by the previously described blocking device14, in order to bring it in a mounting/dismounting position of the handle4enabling the arm7of the handle4to freely slide within the housing8of the base3. This shift is achieved by a user pushing the second lever25of the blocking device14in the direction B, for example. During the step of shifting the first lever13, the latter performs a translational movement in the housing8of the base3along the axial direction X between an aligned position in which the first lever13of the actuation device12is aligned with the sliding axis Y of the arm7of the handle4and a shifted position in which the first lever13of the actuation device12is shifted relative to the sliding axis Y. The mounting and dismounting method then comprises a step of blocking the actuation device12in the mounting/dismounting position by the blocking device14. The blocking device14exerts a force against the actuation device12along the axial direction X in order to block its axial movement in this direction and in order to block its rotation. The lug30is then clipped into the slot33of the first blocking device31ain order to block the translation and the rotation of the rod16. Alternatively, the screwing of the rod16of the blocking device14toward the locking position may allow pushing the actuation device12and shifting it to the right when referring to the plane ofFIG.3, that is to say in the direction of the arrow B, according to the sliding axis Y. During the step of shifting the first lever13, the rod16translates along the axial direction X relative to the base3and toward the actuation device12from an unlocking position in which the rod16is disconnected from the actuation device12toward a locking position in which the rod16exerts a pressure against the actuation device12in order to hold it shifted relative to the sliding axis Y. The rod16of the blocking device14blocks both the translation of the actuation device12thereby inhibiting its return toward its initial position and the rotation of the actuation device12. Hence, the rod16counteracts the return force exerted by the return spring15in the direction opposite to the direction B and the torque also generated by this return spring15on the first lever13. The blocking device14therefore allows providing a pre-assembled door handle assembly1, that is to say not comprising yet the handle4which may be assembled later on, after the insertion of the lock onto the door2. The mounting and dismounting method then comprises a step of inserting the arm7of the handle4into the housing8of the base3in order to enable the mounting of the handle4on the base3or the removal of the arm7of the handle4out of the housing8of the base3in order to dismount the handle4from the base3. In particular, the mounting method comprises an initial step of fastening the base3on the door2of the vehicle. The hinge5at the first end6of the handle4is then mounted on the base3. The mounting method also comprises the previous steps of positioning the actuation device12in the open position of the door2, of shifting the first lever13of the actuation device12relative to the sliding axis Y of the arm7of the handle4by the blocking device14and of blocking the actuation device12in the mounting/dismounting position by the blocking device14. The mounting method then comprises a step of inserting the arm7of the handle4into the housing8of the base3during which a first surface20of the hook10of the arm7pushes the first lever13of the actuation device12toward a direction opposite to the hook10when the arm7is inserted into the housing8of the base3until the first lever13recovers its initial position. The first lever13is then positioned facing a second upper surface21of the hook10. More specifically, the first surface20of the hook10slides on the first lever13of the actuation device12according to a plane C, represented inFIG.3, and exerts a force opposing the return force of the return spring15, thereby causing a slight displacement of the first lever13toward this spring. After a supplementary insertion of the arm7into the housing8, the first lever13then slides along the second upper surface21of the hook10according to a plane D, until recovering its initial position after a movement according to the arrow E, as illustrated inFIG.4. The operator may hear a noise due to the return of the first lever13which is pushed by the return spring15. The first lever13is then engaging the hook10of the handle4. The blocking device14is then displaced in the unlocked position and the first lever13recovers its retracted or rest position, as illustrated inFIG.5. The lug30of the rod16is clipped into the slot of the second blocking device31bin order to block the rod16in the unlocking position. The handle4is thus mounted on the base3. According to the reverse method for dismounting the handle4, when the blocking device14has blocked the first lever13in the dismounting position, the user pulls on the handle4according to a direction opposite to the base3, thereby causing the sliding of the arm7of the handle4inside the housing8of the base3toward the outside until its extraction from the housing8. The hinge5at the first end6of the handle4is then dismounted in order to completely remove the handle4from the base3. A lock may afterwards be fastened on the door2of the vehicle. The present disclosure is described in the foregoing as an example. It is understood that those skilled in the art are capable of carrying out different variations without departing from the scope of the present disclosure. Unless otherwise expressly indicated herein, all numerical values indicating mechanical/thermal properties, compositional percentages, dimensions and/or tolerances, or other characteristics are to be understood as modified by the word “about” or “approximately” in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice, material, manufacturing, and assembly tolerances, and testing capability. As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.” The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure. | 17,434 |
11859416 | DETAILED DESCRIPTION Example embodiments of a power-operated closure latch assembly for use in a motor vehicle closure system will now be described more fully with reference to the accompanying drawings. To this end, the example embodiments of the closure latch assembly are provided so that the disclosure will be thorough and will fully convey its intended scope to those who are skilled in the art. Accordingly, numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of particular embodiments of the present disclosure. However, it will be apparently to those skilled in the art that specific details need not be employed, that the example embodiments may be embodied in many different forms, and that the example embodiments should not be construed to limit the scope of the present disclosure. In some parts of the example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. In the following detailed description, the expression “closure latch assembly” will be used to generally indicate any power-operated latch device adapted for use with a vehicle closure panel and which is configured to provide at least one of a power cinch feature and a power release feature. Additionally, the expression “closure panel” will be used to indicate any element mounted to a structural body portion of a motor vehicle and which is moveable between a fully-open position and a fully-closed position, respectively opening and closing an access to a passenger or storage compartment of the motor vehicle. Therefore, the closure panel includes, without limitations, decklids, hoods, tailgates, liftgates, bonnet lids, and sunroofs in addition to the sliding or pivoting passenger doors of the motor vehicle. FIG.1illustrates a motor vehicle10having a body11defining a front compartment, which in some embodiments may be an engine compartment and in other embodiments may be a storage compartment. In this non-limiting example of motor vehicle10, a closure panel, configured as a decklid (or “hood”)12, is pivotably mounted to body11for movement relative to the front compartment between a fully-closed position12A, a partially-open or pop-up position12B; and a fully-open position12C. Decklid12may be manually released via pulling a release handle14located within a passenger compartment20of vehicle10and which functions to actuate a latch release mechanism associated with a closure latch assembly16for releasing decklid12and permitting subsequent movement of decklid12to its pop-up position. A release cable18is shown to interconnect release handle14to the latch release mechanism associated with closure latch assembly16. A safety latch mechanism also associated with closure latch assembly16can then be manually actuated to permit decklid12to be moved from its pop-up position into its fully-open position. Release of the safety latch mechanism can be provided via a second pulling of release handle14. Closure latch assembly16is, in this non-limiting embodiment, secured to a structural portion of vehicle body11adjacent to the front compartment and is configured to releasably engage a striker22mounted to an underside of decklid12. In addition to this otherwise conventional mechanical release of closure latch assembly16, the present disclosure is directed to providing closure latch assembly16with a power release function and a power cinch function. A detailed description of a non-limiting embodiment of a power-operated version of closure latch assembly16, constructed in accordance with the teachings of the present disclosure, will now be provided with reference toFIGS.2through18. Referring initially toFIGS.2A and2B, closure latch assembly16is generally shown to include a latch mechanism30, a latch release mechanism32, a spring-loaded lift mechanism34, a latch cinch mechanism36, and a power actuator38. As will be detailed, power actuator38is operable to control actuation of latch release mechanism32to provide a power release function and to control actuation of latch cinch mechanism36to provide a power cinch function. A latch controller37is schematically shown in communication with power actuator38for controlling actuation thereof in response to sensor signals inputted to latch controller37from one or more latch sensors39. The sensor signals can include, without limitation, a power release request (i.e. via key fob or push button) as well as positional signals indicative of the position of various components associated with one or more of the above-noted mechanism. While only shown schematically, power actuator38is intended to be configured to include, in this non-limiting example, an electric motor that is operable to actuate a drive mechanism operably associated with latch release mechanism32and latch cinch mechanism36, as will be detailed. Closure latch assembly16also includes a frame plate and cover plate configured to define a latch housing (not shown) which supports each of the above-noted mechanisms and power actuator38. The latch housing is fixedly secured to an edge portion of vehicle body11adjacent to the front compartment and defines an entry aperture through which striker22travels upon movement of decklid12relative to vehicle body11. Latch mechanism30is shown, in this non-limiting example, as a single ratchet and pawl arrangement including a ratchet40and a pawl42. Pawl42may be operably connected to release handle14via release cable18to impart a pivoting of pawl42, illustratively in a clockwise direction as viewed inFIG.2A, in response to an activation of release handle14. Ratchet40is supported in the latch housing via a ratchet pivot post44for rotational movement between several distinct positions including a striker release position, a secondary striker capture position, a cinched striker capture position, a primary striker capture position, and an overtravel striker capture position. Ratchet40is configured to include a primary latch shoulder48and a secondary latch shoulder49. A ratchet biasing mechanism or member, schematically indicated by an arrow50, is adapted to normally bias ratchet40to rotate about ratchet pivot post44in a first or “releasing” direction toward its striker release position. Pawl42is supported in the latch housing by a pawl pivot post52for rotational movement between a ratchet holding position and a ratchet releasing position. A pawl biasing mechanism or member, schematically indicated by an arrow54, is adapted to normally bias pawl42toward its ratchet holding position. Pawl is42is configured to include a pawl latch lug56and a pawl release lug58.FIGS.2A and2Billustrate ratchet40held in its primary striker capture position by pawl42when pawl42is located in its ratchet holding position due to pawl latch lug56engaging primary latch shoulder48on ratchet40. The drive mechanism is shown to include a drive cam60comprised of a drive cam lift lever62, a drive cam pawl release lever64, and a drive cam cinch lever66, all of which are connected in a “stacked” arrangement for common rotation about a drive cam pivot post68. While shown as distinct components, the above-noted levers of drive cam60can be formed together as a single drive cam member as an alternative to the multi-piece configuration shown. As will be detailed, drive cam60is only rotated in a single or “actuation” direction (i.e. counterclockwise inFIG.2Aand clockwise inFIG.2B) via actuation of the electric motor associated with power actuator38. As will be detailed, drive cam lift lever62is operably associated with lift mechanism34, drive cam pawl release lever64is operably associated with latch release mechanism32, and drive cam cinch lever66is operably associated with latch cinch mechanism36. Lift mechanism34is generally shown to include a lift lever70and a lift lever spring72. Lift lever70includes a spring plate segment74and a striker plate segment76, both of which are connected for common rotation about a lift lever pivot post78. While not limited thereto, lift lever pivot post78and pawl pivot post52may be commonly aligned to define a common pivot axis. Lift lever spring72has a first spring end segment80coupled to a stationary lug82extending from the latch housing and a second spring end segment84coupled to a retention lug86extending from spring plate segment74of lift lever70. Lift lever spring72is operable to normally bias lift lever70in a pop-up direction (i.e. counterclockwise inFIG.2Aand clockwise inFIG.2B). Striker plate segment76of lift lever70has a striker lug88that is adapted to selectively engage striker22. Latch cinch mechanism36is shown, in this non-limiting embodiment, to generally include a cinch lever90, a cinch pawl92, and a transmission lever94. Cinch lever90is pivotably mounted to the latch housing via a cinch lever pivot post96. Cinch lever pivot post96may be commonly aligned with ratchet pivot post44to define a common pivot axis. A cinch lever biasing mechanism or member, schematically indicated by an arrow97, is adapted to normally bias cinch lever90toward a first or “home” position. Cinch lever90includes a first pivot lug segment98and a second pivot lug segment100. Cinch pawl92is pivotably coupled to first pivot lug segment98on cinch lever90via a cinch pawl pivot post102and has a cinch pawl drive lug104configured to be selectively engageable with ratchet40. Transmission lever94has a first end segment pivotably coupled to second pivot lug segment100on cinch lever90via a transmission lever pivot post106, a second end segment defining a drive slot108, and an intermediate segment defining a transmission drive lug110. As will be hereinafter detailed,FIGS.3A through18Bprovide a series of sequential front and rear plan views of closure latch assembly16illustrating rotation of drive cam60via power actuator38to initiate and complete a power-operated primary latch release operation (FIGS.3A-7B), to initiate and complete a power-operated safety latch release operation (FIGS.8A-8C), and to initiate and complete a dual-stage decklid cinch operation (FIGS.9A-18B). Thus, closure latch assembly16is equipped with an “integrated” power-operated actuation arrangement having the single power actuator38located within the latch housing. The sequential views illustrate movement of the various components and mechanisms associated with closure latch assembly16to provide these distinct operations. FIGS.3A and3Billustrate closure latch assembly16operating in a primary latched mode for holding decklid12in its fully-closed position relative to body portion11of vehicle10. With closure latch assembly16in its primary latched mode, latch mechanism30is operating in a primary latched state with ratchet40located in its primary striker capture position and pawl42located in its ratchet holding position. In addition, latch release mechanism32is shown operating in a non-actuated state with drive cam60located in a first or “home” position. Striker22is shown captured/retained within striker guide channel46of ratchet40such that striker22engages and acts on striker lug88of striker plate segment76so as to forcibly locate lift lever70in a first or “non-deployed” position, in opposition to the biasing of lift lever spring72, thereby placing lift mechanism34in a spring-loaded state. Finally, latch cinch mechanism36is shown operating in an uncoupled state with cinch lever90located by cinch lever biasing member97in a first or “home” position. Note that location of cinch lever90in its home position also results in cinch pawl92and transmission lever94being located in their respective first or “home” positions. FIGS.4A and4Billustrate, in comparison toFIGS.3A and3B, respectively, initiation of the power release operation in response to latch controller37receiving a power release signal. Specifically, power actuator38has been actuated such that the electric motor causes drive cam60to begin rotating in the actuation direction (see arrow114) from its home position toward a second or “pawl released” position (shown inFIGS.6A,6B). This initial driven rotation of drive cam60in the actuation direction causes a first pawl trigger lug116formed on drive cam pawl release lever64to engage pawl release lug58on pawl42, as indicated by arrow “A” inFIG.4A. This engagement causes pawl42to begin moving from its ratchet holding position toward its ratchet releasing position, in opposition to the biasing of pawl biasing member54. In addition, a profiled cam edge surface118formed on drive cam lift lever62moves into engagement with a follower lug120formed on spring plate segment74of lift lever70. FIGS.5A and5Billustrate, in comparison toFIGS.4A and4B, respectively, continued driven rotation of drive cam60in the actuation direction by power actuator38causes continued movement of pawl42toward its ratchet releasing position due to first pawl trigger lug116on drive cam pawl release lever64continuing to forcibly act on pawl release lug58on pawl42(see arrow “A” ofFIG.5A). In addition, the profile of cam edge surface118on drive cam lift lever62is configure to forcibly act on follower lug120on spring plate segment74, as indicated by arrow “B” ofFIG.5A, for causing lift lever70to rotate slightly in a downward (i.e. clockwise inFIG.5Aand counterclockwise inFIG.5B) direction. This slight rotation of lift lever70causes striker22to disengage striker lug88on striker plate segment26, as indicated by arrow “C”, thereby reducing the force exerted by lift lever spring72on striker22. With striker lug88displaced from engagement with striker22, the only forces acting on striker22in the releasing direction are the seal loads which may result in reduced ratchet/striker noise upon release of latch mechanism30. FIGS.6A and6Billustrate, in comparison toFIGS.5A and5B, respectively, that continued driven rotation of drive cam60in the actuation direction into its pawl released position functions to shift latch release mechanism32from its non-actuated state into an actuated state such that pawl42is now located in its ratchet releasing position. As such, pawl latch lug56on pawl42is disengaged from primary latch shoulder48on ratchet40(as indicated by arrow “D” inFIG.6B) for defining a primary unlatched state for latch mechanism30. Simultaneously, the profile of cam edge surface118on drive cam lift lever62is configured to now cause follower lug120(see arrow “B”) to rotate lift lever70slightly upwardly until striker lug88re-engages striker22. At this point, lift mechanism34shifts from its spring-loaded state into a spring-released (i.e. “pop-up”) state and initiates a pop-up function. FIGS.7A and7Billustrate, in comparison toFIGS.6A and6B, respectively, that shifting of latch mechanism30into its primary unlatched state permits ratchet biasing member50to forcibly drive ratchet40from its primary striker capture position into its secondary striker capture position. Concurrently, the shifting of lift mechanism34into its spring-released state causes lift lever spring72to forcibly drive lift lever70in the pop-up direction from its non-deployed position into a second or “deployed” position. As will be detailed, a safety latch mechanism130(FIG.8C) is operable in a safety latched state to engage and hold ratchet40in its secondary striker capture position so as to define a secondary latched state for latch mechanism30. With ratchet40held in its secondary striker capture position by safety latch mechanism130, striker22is prevented from exiting striker guide channel46via engagement with a hooked end segment (i.e. “safety hook”)132formed on ratchet40. However, pivotal movement of lift lever70to its deployed position results in striker lug88on striker plate segment76engaging and forcibly driving striker22upwardly (see arrow “E”), thereby causing lift mechanism34to move decklid12from its fully-closed position into its pop-up position. As such, closure latch assembly16has been shifted from its primary latched mode into a secondary latched mode. Note also that follower lug120has disengaged cam edge surface118and now slides along a follower edge surface134until it abuts a stop shoulder136formed on drive cam lift lever62(see arrow “F”). The interaction between follower lug120on spring plate segment74and stop shoulder136on drive cam lift lever62acts to positively locate lift lever70in its deployed position and complete the pop-up function. First pawl trigger lug116on drive cam pawl release lever64is also shown to have moved past and out of engagement with pawl release lug58, thereby allowing pawl biasing member54to bias pawl42to move toward its ratchet holding position. The pop-up position of decklid12is selected to be raised a predetermined amount with respect to its fully-closed position. The predetermined amount of decklid travel is, in this non-limiting embodiment, selected for the pop-up position of decklid12to be about 25 mm. FIGS.8A and8Billustrate latch mechanism30operating in its secondary latched state and spring-loaded lift mechanism34operating it its spring-released state whileFIG.8Cillustrates safety latch mechanism130operating in its safety latched state for holding ratchet40in its secondary striker capture position. Safety latch mechanism130is best shown inFIG.8Cto generally include a coupling link140and a safety pawl142. Coupling link140has a first end segment144engaged with a drive lug146formed on pawl42, a second end segment148pivotally connected to safety pawl142via a first coupling link pivot post150, and an intermediate segment152pivotally connected to a leg extension segment154of ratchet40via a second coupling link pivot post156. Safety pawl142is mounted to the latch housing by a safety pawl pivot post160for movement between a first or “ratchet blocked” position (shown) and a second or “ratchet unblocked” position. A safety pawl biasing mechanism or member, schematically indicated by an arrow158, is arranged to normally bias safety pawl142toward its ratchet blocked position. In its ratchet blocked position, a blocker lug162on safety pawl142engages secondary latch shoulder49on ratchet40, thereby mechanically holding ratchet40in its secondary striker capture position. Thus,FIG.8Cillustrates safety latch mechanism130operating in its safety latched state and latch mechanism30operating in its secondary latched state. Continued driven rotation of drive cam60in its actuation direction from its pawl released position toward a third or “safety pawl released” position causes a second pawl trigger lug164on drive cam pawl release lever64to engage pawl release lug58on pawl42, as indicated by arrow “G”. As such, pawl42is again rotated about pawl pivot52, in opposition to the biasing of pawl biasing member54, toward its ratchet releasing position which, in turn, causes corresponding movement of coupling link140due to engagement of pawl drive lug146with first end segment144of coupling link140. Such movement of coupling link140results in movement of safety pawl142from its ratchet blocked position into its ratchet unblocked position, whereby blocker lug162is released from engagement with secondary latch shoulder49on ratchet40, thereby establishing a safety unlatched state for safety latch mechanism130and an unlatched state for latch mechanism30. Specifically, with safety pawl142located in its ratchet unblocked position, ratchet biasing member50is permitted to drive ratchet40from its secondary striker capture position into its striker release position, thereby releasing striker22from ratchet40so as to permit subsequent manual movement of decklid12from its pop-up position to its fully-open position since striker22is no longer retained within guide channel46nor movement limited by safety hook segment132. In this arrangement, closure latch assembly16is, due to shifting of safety latch mechanism130into its safety unlatched state, shifted from its secondary latched mode into its released mode. Once ratchet40is located in its striker release position, power actuator38is placed in a power-off state so as to stop further rotation of drive cam60. FIGS.3A through8Bhave clearly illustrated initiation and completion of the power release function via driven rotation of drive cam60in the actuation direction from its home position (FIGS.3A,3B) into its pawl released position (FIGS.6A,6B) and further into its safety pawl released position (FIGS.8A-8C) due to actuation of power actuator38. Now,FIGS.9A through17Bwill be described with similar detail to clearly illustrate initiation and completion of a dual-stage cinch function operable for moving decklid12from its pop-up position (FIGS.9A,9B) to its fully-closed position (FIGS.17A,17B) in response to driven rotation of drive cam60in the actuation direction from its safety pawl released position back to its home position. In accordance with the present disclosure, the dual-stage cinch function associated with closure latch assembly16includes a first or “non-driven” cinching stage and a second or “driven” cinching stage. The first cinching stage of the cinch operation functions to move decklid12from a first stage start position to a first stage end position using only the weight of the decklid12. Preferably, the first stage start position of decklid12corresponds to the pop-up position of decklid12, which, as previously noted, is selected to be about 25 mm raised relative to the fully-closed position in accordance with this non-limiting embodiment. The first stage end position for decklid12can be selected as required for each vehicular application but, in this non-limiting example, is selected to be about 8 mm raised relative to the fully-closed position of decklid12. To provide the first cinching stage, power actuator38and drive cam60are configured to move lift lever70from its spring-released (i.e. deployed) position to its spring-loaded (i.e. non-deployed) position, in opposition to the biasing of lift lever spring72, to permit decklid12to move (under its own weight) from its first stage start/pop-up position into its first stage end position. Thus, the term “non-driven” is intended to define that ratchet40is not cinched via a power-operated arrangement, such as via latch cinch mechanism36, during the first cinching stage so as to inhibit pinching of fingers. FIGS.9A and9B, in comparison toFIGS.8A and8B, respectively, illustrate initiation of the first cinching stage by power actuator38being placed in a power-on state to cause driven rotation of drive cam60in the actuation direction from its safety pawl released position to a fourth or “first stage cinch start” position in response to decklid12being manually moved from its fully-open position to its pop-up position. Such manual movement of decklid12to its pop-up position also results in latch mechanism30shifting back into its secondary latched state with safety latch mechanism130shifted back into its safety latched state. As such, ratchet40is driven by striker22into its secondary striker capture position, whereat blocker lug162on safety pawl142engages secondary latch shoulder49. In addition,FIGS.9A and9Balso illustrate follower lug120on lift lever70now engaging a cinch edge surface170(See arrow “H”) formed on drive cam lift lever62and which is profiled to cause lift lever70to pivot about lift lever pivot post78in the downward direction opposing the normal biasing of lift lever spring72. Such downward pivotal movement of lift lever70towards its non-deployed position causes striker22and decklid12to move downward, due to the weight of decklid12, as striker22maintains engagement with striker lug88(See arrow “E”). FIGS.10A and10B, in comparison toFIGS.9A and9B, respectively, illustrate continued driven rotation of drive cam60in the actuation direction from its first stage cinch start position toward a fifth or “first stage cinch end” position. Concurrently, the weight of decklid12continues to cause striker22to act on ratchet40within guide channel46and forcibly rotate ratchet40, in opposition to ratchet biasing member50, from its secondary striker capture position toward its cinched striker capture position. As such, decklid12moves downwardly from its pop-up position toward its cinched position. Note also that striker22continues to act on striker lug88for forcibly rotating lift lever70, in opposition to lift lever spring72, toward its non-deployed position. In addition, the profile of cinch edge surface170also assists in driving lift lever70toward its non-deployed position during such rotation of drive cam60toward its first stage cinch end position. Furthermore, drive cam60has rotated such that a cinch lever drive post172extending from drive cam cinch lever66is now shown positioned within drive slot108of transmission lever94, thereby coupling latch cinch mechanism36to drive cam60. As such, latch cinch mechanism36is shifted from its uncoupled state into a coupled state. At this point in the first cinching stage, cinch pawl92has not yet moved into engagement with ratchet40. FIGS.11A and11B, in comparison toFIGS.10A and10B, respectively, illustrate the continued rotation of ratchet40toward its cinched striker capture position due to continued engagement with striker22, and also illustrate the continued rotation of lift lever70toward its non-deployed position due to striker22acting on striker lug88and due to cinch edge surface170on drive cam lift lever62acting on follower lug120. These drawings illustrate drive cam60rotated to its first stage cinch end position such that decklid12is now located in its cinched position (between its pop-up and fully-closed position) raised about 8 mm relative to its fully-closed position. This cinched position of decklid12defines the end point of the first cinching stage and the start point of the second cinching stage of the dual-stage cinch operation with ratchet40located in its cinched striker capture position. Note that engagement of cinch lever drive post172within drive slot108has caused drive cam cinch lever66to initiate movement of transmission lever94from its home position toward a second or “cinched” position. Such initial movement of transmission lever94also causes corresponding movement of both cinch pawl92and cinch lever90from their respective home positions toward their second or “cinched” positions. However, cinch pawl92is still not forcibly acting on ratchet40(See arrow “I”). Cinch edge surface170on drive cam lift lever62continues to drive follower lug120to rotate lift lever70in a downward direction toward its non-deployed position. However, striker22and decklid12no longer follow along with continued rotation of lift lever70due to seal loading acting thereon. FIGS.12A and12Bare generally similar toFIGS.11A and11B, respectively, but now illustrate drive cam60slightly further rotated by power actuator38in the actuation direction from its first stage cinch end position into a sixth or “second stage cinch start” position whereat cinch pawl92has moved into engagement with ratchet40(See arrow “I”) so as to initiate the second cinching stage of the dual-stage cinch operation. Note that transmission lever94continues to be driven by drive cam cinch lever66toward its cinched position (due to retention of cinch lever drive post172within drive slot108) which likewise continues to drive cinch pawl92and cinch lever90toward their respective cinched positions. FIGS.13A and13Bare generally similar toFIGS.12A and12B, respectively, and illustrate slightly further rotation of drive cam60in the actuation direction toward a seventh or “second stage cinch end” position. Such rotation of drive cam60causes drive cam cinch lever66to continue movement of the components of latch cinch mechanism36such that cinch pawl92continues to move toward its cinched position. Since cinch pawl92is now acting on ratchet40, such movement of cinch pawl92towards its cinched position also acts to forcibly drive ratchet40from its cinched striker capture position toward its primary striker capture position. This driven cinching movement of ratchet40causes ratchet40to act on and move striker22which, in turn, causes decklid12to move from its cinched position toward its fully-closed position. FIGS.14A and114Bare generally similar toFIGS.13A and13B, respectively, and illustrate decklid12now located in its fully-closed position with cinch pawl92located in its cinched position, with ratchet40located by cinch pawl92into its primary striker capture position, and with pawl42located in its ratchet holding position, all in response to driven rotation of drive cam60into its second stage cinch end position. Note that further rotation of drive cam60no longer causes downward movement of lift lever70which is now positioned in its non-deployed position due to follower lug120acting on a neutral surface segment180formed on cinch edge surface170. FIGS.15A and15Billustrate, in direct comparison toFIGS.14A and14B, respectively, continued driven rotation of drive cam60via power actuator38in the actuation direction into an eighth or “overtravel” position which, in turn, locates each of transmission lever94, cinch pawl92, and cinch lever90in their respective cinched position. As such, ratchet40(via its continued engagement with cinch pawl92) is moved to its overtravel striker capture position which is, in this non-limiting embodiment, located about 2 mm past its primary striker capture position. The clearance between striker22and striker lug88on lift lever70results in all cinching of striker22being caused via engagement of striker22with ratchet40. The generally “on-center” alignment between drive cam cinch lever66and transmission lever94generates the maximum force within the system. FIGS.16A and16Billustrate, in direct comparison toFIGS.15A and15B, respectively, that continued driven rotation of drive cam60in its actuation direction past its overtravel position causes ratchet40to move back toward its primary striker capture position and also acts to re-engage striker lug88on lift lever70with striker22.FIGS.17A and17Billustrate the completion of the second cinching stage of the dual-stage cinch operation with decklid12held by latch mechanism30in its fully-closed position. In particular, power actuator38has now driven drive cam60into a ninth or “cinch complete” position with latch mechanism30in its primary latched state, latch release mechanism32in its non-actuated state, and lift mechanism34in its spring-loaded state. Finally,FIGS.18A and18Billustrate continued driven rotation of drive cam60from the cinch complete position back into its home position such that latch cinch mechanism36is returned (i.e. “reset”) into its uncoupled state. Thus, a single rotation of drive cam60is used to provide the power release of latch mechanism30, the power release of safety latch mechanism130, the dual-stage cinching function including power cinching of latch cinch mechanism36, and the resetting of closure latch assembly16. The present disclosure is directed to closure latch assembly16having latch mechanism30operable to releasably engage striker22, latch release mechanism32operable to shift latch mechanism30from a latched state into an unlatched state, and power-operated actuator38operable for selectively actuating latch release mechanism32. Closure latch assembly16also includes spring-loaded lift mechanism34that is operable to move the closure panel, herein described as decklid12, from its fully-closed position to its partially-open position following actuation of latch release mechanism32. Coordinated actuation of latch release mechanism32and safety latch mechanism130via power-operated actuator38provides the decklid power release function. The present disclosure is further directed to closure latch assembly16having latch cinch mechanism36that can be shifted from an uncoupled state into a coupled state via power-operated actuator38to provide the dual-stage decklid cinching function. Latch cinch mechanism36is operable in its uncoupled state to permit decklid12to move from its pop-up position to its cinched position, thereby establishing the first, non-driven cinching stage. Latch cinch mechanism36is operable in its coupled state to mechanically engage latch mechanism30and cause decklid12to move from its cinched position into its fully-closed position, thereby establishing the second, driven cinching stage. Upon completion of the second cinching stage, power-operated actuator38is reset in anticipation of a request for a subsequent power release function. A single actuator arrangement is employed for power-operated actuator38which is configured to control the coordinated actuation of latch release mechanism32and safety latch mechanism130, the resetting of spring-loaded lift mechanism34, and the shifting of latch cinch mechanism36into its coupled state. To this end, a single cam arrangement, herein disclosed as drive cam60, is driven in a single (i.e., “actuation”) direction from a home position through a series of distinct actuation positions to provide these coordinated power release, power cinch and resetting functions. While not shown, the actuation of power actuator38via latch controller37is controlled in response to a power-release signal from a remote keyless entry system (via actuation of a key fob or proximity) to provide these advanced convenience features. As noted, closure latch assembly16ofFIGS.2A-18Bis equipped with an “integrated” power actuator38configured to provide control over both the power release and the power cinch functions. However, some closure latch assemblies are configured to work in conjunction with an external cinch actuator that is separate and distinct from an internal power release actuator. To accommodate such arrangements, the present disclosure also contemplates an alternative version of closure latch assembly16, identified as closure latch assembly16′ inFIGS.19A through28B, and to which the following detailed description is directed. A detailed description of a non-limiting example embodiment of closure latch assembly16′, constructed in accordance with the teachings of the present disclosure, will now be provided. Referring initially toFIGS.19A and19B, closure latch assembly16′ is generally shown to include a latch mechanism200, a latch release mechanism202, safety latch mechanism130(FIG.8C), a power release actuator204, and an “integrated” lift and cinch mechanism206, all of which are supported within the latch housing. Lift and cinch mechanism206is considered to be “integrated” because it combines the functions of lift mechanism34and latch cinch mechanism36of closure latch assembly16into a common mechanism to provide reduced parts and simplify operation. Power release actuator204is operable for controlling actuation of latch release mechanism202which, in turn, controls coordinated actuation of latch mechanism200and safety latch mechanism130. While only schematically shown, power release actuator204includes an electric motor and latch release mechanism202includes a revised version of drive cam60which is driven by the electric motor. In addition, a remotely-located power cinch actuator208is provided for controlling actuation of lift and cinch mechanism206to provide a dual-stage decklid cinch operation. As before, the latch housing of closure latch assembly16′ is fixedly secured to vehicle body11adjacent to the front compartment and defines an entry aperture through which striker22travels in response to movement of decklid12relative to vehicle body11. Latch mechanism200is shown, in this non-limiting embodiment, to be generally similar to latch mechanism30and again includes a pawl and ratchet arrangement having ratchet40and pawl42. Ratchet40is supported in the latch housing via ratchet pivot post44for rotational movement between several distinct positions including the striker release position, the secondary striker capture position, the cinched striker capture position, the primary striker capture position, and the overtravel striker capture position. Ratchet40includes primary latch shoulder48and secondary latch shoulder49. Ratchet biasing member, schematically indicated by arrow50, normally biases ratchet40toward its striker release position. Pawl42is supported in the latch housing via pawl pivot post52for movement between its ratchet holding position and its ratchet releasing position. Pawl biasing member, schematically indicated by arrow54, normally biases pawl42toward its ratchet holding position. Pawl42includes pawl latch lug56and pawl release lug58.FIGS.19A and19Billustrate ratchet40held in its primary striker capture position by pawl42located in its ratchet holding position due to pawl latch lug56engaging primary latch shoulder48on ratchet40. Thus, closure latch assembly16′ is operating in its primary latched mode. Lift and cinch mechanism206is shown, in this non-limiting embodiment, to generally include a lift/cinch lever212, a cinch pawl214, and a lift lever spring216. Lift/cinch lever212is pivotably mounted to the latch housing via a lift/cinch lever pivot post218which is shown to be commonly aligned with ratchet pivot post44to define a common pivot axis. Lift/cinch lever212is configured to include a lift lever segment220and a cinch lever segment222. Lift lever segment220includes an elongated striker lug224adapted to selectively engage striker22. Cinch lever segment222includes a body portion226and an elongated actuation portion228extending from body portion226. Lift lever spring216has a first spring end230coupled to a stationary lug232extending from the latch housing and a second spring end234coupled to a retention lug236extending from actuation portion228of lift/cinch lever212. Lift lever spring216is operable to normally bias lift/cinch lever212in a pop-up direction (i.e. clockwise inFIG.19Aand counterclockwise inFIG.19B). Power cinch actuator208is schematically shown to act on an end segment240of actuation portion228of lift/cinch lever212and is operable for pivoting lift/cinch lever212about pivot post218, in opposition to the biasing of lever spring216. Cinch pawl214is shown to have a first end segment250pivotably coupled to body portion226of lift/cinch lever212via a cinch pawl pivot post252, a second end segment254having a guide lug256configured to slide along a profiled cam surface formed on a guide rail portion258of the latch housing, and an intermediate segment260having a cinch pawl drive lug262configured to selectively engage a ratchet drive lug264extending from ratchet40. A cinch pawl biasing member, schematically indicated by arrow266, is operable to normally bias cinch pawl214in an engagement direction (i.e. clockwise inFIG.19Aand counterclockwise inFIG.19B) to maintain sliding engagement of guide lug256with the cam surface on guide rail portion258of the latch housing. As will be hereinafter detailed,FIGS.19A-20Billustrate a power release operation provided in response to actuation of power release actuator204,FIGS.21A and21Billustrate a manual decklid closing operation, andFIGS.22A-28Bare a series of sequential views illustrating a dual-stage power cinch operation provided in response to actuation of power cinch actuator208. Thus,FIGS.19A-28Bare provided to illustrate movement of the various components of closure latch assembly16′ required to provide these distinct operations. FIGS.19A and19Billustrate closure latch assembly16′ operating in its primary latched mode for holding decklid12in its fully-closed position. With closure latch assembly16′ in its primary latched mode, latch mechanism200is operating in its primary latched state with ratchet40held in its primary striker capture position by pawl42located in its ratchet holding position. In addition, latch release mechanism202is operating in its non-actuated state. Striker22is captured/retained within striker guide channel46of ratchet40such that striker22engages and acts on striker lug224on lift lever segment220of lift/cinch lever212so as to forcibly locate and hold lift/cinch lever212in a first or “non-deployed” position, in opposition to the normal biasing of lift lever spring216, thereby placing lift/cinch lever212of lift and cinch mechanism206in its spring-loaded state. Cinch pawl214is shown biased into a first or “coupled” position via cinch pawl biasing member266such that its guide lug256engages a first or “inner” cam surface272formed on guide rail portion258of the latch housing, thereby placing cinch pawl214of lift and cinch mechanism206in its coupled state. FIGS.20A and20Billustrate closure latch assembly16′ operating in its released mode following completion of a power release operation which causes decklid12to initially move from its fully-closed position to its pop-up position (via power release of latch release mechanism202) and which subsequently permits decklid12to move from its pop-up position toward its fully-open position (via power release of safety latch mechanism130). To provide this two-part power release operation, power release actuator204functions to shift latch release mechanism202from its non-actuated state into its actuated state for causing pawl42to be moved from its ratchet holding position into its ratchet releasing position, whereby ratchet biasing member50is permitted to move ratchet40from its primary striker capture position into its secondary striker capture position. Concurrently, lift lever spring216is permitted to move lift/cinch lever212from its non-deployed position toward a second or “deployed” position which assists in moving decklid12to its pop-up position via engagement of striker lug224with striker22, thereby placing lift/cinch lever212of lift and cinch mechanism206in its spring-released state. As before, safety latch mechanism130is operable in its safety latched state to hold ratchet40in its secondary striker capture position (via engagement of safety pawl lug162with ratchet secondary latch shoulder49) to define the secondary latched state of latch mechanism200. Continued actuation of power release actuator204functions to shift safety latch mechanism130into its safety unlatched state to disengage safety pawl142from ratchet40, whereby ratchet biasing member50drives ratchet40to its ratchet released position (shown). Movement of lift/cinch lever212to its deployed position also results in concurrent movement of cinch pawl214from its coupled position to a second or “uncoupled” position, thereby placing cinch pawl214of lift and cinch mechanism206in its coupled state such that guide lug256engages a second or “outer” cam surface274formed on guide rail portion258of the latch housing. As seen, striker22is released from ratchet40, thereby permitting opening movement of decklid12. FIGS.21A and21Bare generally similar toFIGS.20A and20B, respectively, but now illustrate a manual decklid closing operation in which the weight of decklid12(FHOOD), schematically indicated by arrow280, is shown acting on primary latch shoulder48of ratchet40. This closing force280acts, in opposition to ratchet biasing member50, to rotate ratchet40from its striker release position (shown) toward its secondary striker capture position whereat safety pawl142of safety latch mechanism130re-engages secondary latch shoulder49on ratchet40and establishes the secondary latched state of latch mechanism200such that decklid12is held in its pop-up position. In accordance with the present disclosure, closure latch assembly16′ is configured to provide a dual-stage decklid cinch function via remotely-located power cinch actuator208controlling actuation of lift and cinch mechanism206. As before, the first, non-driven cinching stage is operable to permit decklid12to move under its own weight from its pop-up position to its cinched position while the second, driven cinching stage is operable to drive decklid12from its cinched position to its fully-closed position. In this non-limiting embodiment, the pop-up position of decklid12is selected to be about 25 mm raised relative to the fully-closed position while the cinched position of decklid12is selected to be about 8 mm raised relative to the fully-closed position. In this regard,FIGS.22A-24Billustrate the first cinching stage whileFIGS.25A-28Billustrate the second cinching stage. Referring toFIGS.22A and22B, closure latch assembly16′ is shown in its secondary latched mode with decklid12held by latch mechanism200in its pop-up position. As such, latch mechanism200has been shifted back into its secondary latched state with safety latch mechanism130shifted into its safety latched state such that safety pawl142is located in its ratchet blocked position with its blocking lug162engaging secondary latch shoulder49on ratchet40. As previously noted, the pop-up position of decklid12preferably corresponds to the first stage start position for the first cinching stage. With decklid12located in this position, striker22is engaging striker lug224on lift/cinch lever212, as indicated by arrow280, with lift/cinch lever212located in its deployed position. When sensors39detect an appropriate positioned signal, such as the location of ratchet40in its secondary striker capture position, power cinch actuator208is actuated to drive lift/cinch lever212from its deployed position toward its non-deployed position, in opposition to the biasing of lift lever spring216. This actuation of power cinch actuator208is provided by an actuation force, indicated by force line286, acting (i.e. pulling) on end portion240of actuation portion228of lift/cinch lever212. This actuation force286may be generated by a cable pulling on lift/cinch lever212via a motor-driven cable/driven type cinch actuator. As an alternative, a linear-type cinch actuator can be used to generate and exert the actuation force286. Thus,FIGS.22A and22Billustrate initiation of the first cinching stage. During the first cinching stage, cinch pawl drive lug262on cinch pawl214remains disengaged from ratchet drive lug264on ratchet40. In particular,FIG.22Ashows cinch pawl214located in its uncoupled position with its guide lug256in engagement with second cam surface274. As such, power cinch actuator208functions to move lift/cinch lever212downwardly towards its non-deployed position such that the weight (FHOOD)280is solely responsible for movement of decklid12from its pop-up position to its cinched position. FIGS.23A and23Billustrate continuation of the first cinching stage with striker22continuing to drive ratchet40toward its cinched striker capture position. Concurrently, power cinch actuator208continues to drive lift/cinch lever212towards its non-deployed position.FIG.23Ashows guide lug256on cinch pawl214exiting engagement with second cam surface274along a transition surface276as cinch pawl214moves from its uncoupled position toward its coupled position. However, cinch pawl drive lug262is still displaced from engagement with ratchet drive lug264. Thus, the weight (FHOOD) of decklid12continues to provide the first cinching stage. FIGS.24A and24Billustrate completion of the first cinching stage upon continued actuation of power cinch actuator208moving lift/cinch lever212toward its non-deployed position with decklid12located in its cinched position and held there by ratchet40being located in its cinched striker capture position. However, striker22disengages striker lug224upon continued pivotal movement of lift/cinch lever212due to seal load influences. Note that continued movement of lift/cinch lever212towards its non-deployed position causes continued movement of cinch pawl towards its coupled position. As shown inFIG.24A, cinch pawl drive lug262is still disengaged from ratchet drive lug264at the end of the first cinching stage. FIGS.25A and25Bare generally similar toFIGS.24A and24B, respectively, but illustrate initiation of the second cinching stage resulting from continued actuation of power cinch actuator208. Specifically, cinch pawl214is now shown located in its coupled position with its guide lug256in sliding engagement with first cam surface272and cinch pawl drive lug262in engagement with ratchet drive lug264. Thus, cinch pawl214of lift and cinch mechanism206has been shifted into its coupled state. Continued movement of lift/cinch lever212towards its non-deployed position causes cinch pawl214to forcibly move ratchet40from its cinched striker capture position toward its primary striker capture position. As such, ratchet40acts on striker22to drive decklid12from its cinched position toward its fully-closed position. FIGS.26A and26Bare generally similar toFIGS.25A and25B, respectively, but illustrate that movement of lift/cinch lever212into its non-deployed position results in cinch pawl214driving ratchet40into its primary striker capture position (shown). As such, pawl biasing member54forces pawl42to move into its ratchet holding position relative to ratchet40such that pawl latch lug56is aligned with primary latch shoulder48on ratchet40. Note also that striker lug224on lift/cinch lever212is no longer engaged with striker22such that all cinching of decklid12into its fully-closed position is provided via cinch pawl214. FIGS.27A and27Bare generally similar toFIGS.26A and26B, respectively, but illustrate that continued movement of lift/cinch lever212slightly past its non-deployed position via continued actuation of power cinch actuator208has resulted in cinch pawl214driving ratchet40(via engagement of cinch pawl drive lug262with ratchet drive lug264) into its overtravel striker capture position which, in this non-limiting embodiment, is about 2 mm past the decklid fully-closed position. Finally,FIGS.28A and28Billustrate the end of the second cinching stage with power cinch actuator208shifted into a power-off condition. With no actuation force applied by power cinch actuator208, lift/cinch lever212returns to its non-deployed position and cinch pawl214moves slightly to disengage cinch pawl drive lug262from ratchet drive lug264. Thus, closure latch assembly16′ is now operating in its primary latched mode with latch mechanism200in its primary latched state holding decklid12in its fully-closed position. An emergency release lever300may be pivotally coupled about pawl pivot52and connected with release cable18to allow for a manual release of the latch mechanism200by activation of handle14(e.g. illustratively by a clockwise rotation of emergency release lever300ofFIG.28Aimparted by the activation of cable18represented by arrow A18). Rotation of emergency release lever300imparts a rotation of pawl42towards the ratchet releasing direction. ThroughFIGS.19A to28B, stationary lug232may be illustratively coupled to emergency release lever300to increase the spring tension in lift lever spring216during a manual release to assist driving the lift/cinch lever212in the pop-up direction. In each embodiment of closure latch assembly16,16′, the power cinch operation is divided into two stages. As detailed, the first cinching stage is intended to lower decklid12via lowering of the lift lever70,212from its pop-up height (i.e. 25 mm) to its cinched height (i.e. 8 mm). Due to the weight of decklid12acting on lift lever70,212, decklid12follows along from its partially-open position to its cinched position. This first (i.e. non-driven) stage prevents pinching of fingers. The second cinching stage is intended to cause latch cinch mechanism36and lift and cinch mechanism206to engage and drive ratchet40from its cinched striker capture position into its primary striker capture position, thereby mechanically pulling striker22for moving decklid12from its cinched position into its fully-closed position. A detailed description of an alternative embodiment of a power-operated version of a closure latch assembly300, constructed in accordance with the teachings of the present disclosure, will now be provided with reference toFIGS.29through38of the drawings. Referring initially toFIG.29, closure latch assembly300is generally shown to include a latch mechanism302, a latch release mechanism304, a spring-loaded lift mechanism306, a latch cinch mechanism308, and a power actuator310. As will be detailed, power actuator310is operable to control actuation of a drive mechanism312for actuating latch release mechanism304to provide a power release function and for actuating latch cinch mechanism308to provide a power cinch function. Latch controller37is again schematically shown in communication with power actuator310for controlling actuation thereof in response to sensor signals inputted to latch controller37from one or more latch sensors39. The sensor signals can include, without limitation, a power release request (i.e. via a key fob or push button) as well as positional signals indicative of the position one or more of moveable components of closure latch assembly300. While only schematically shown, power actuator310is configured to include an electric motor that is operable to rotate a drive wheel314associated with drive mechanism312. The electric motor (not shown) is housed within an actuator housing section316of the latch housing and has a rotary motor shaft, schematically shown by line318, arranged to rotate about a rotary axis320. The latch housing is shown to further include a frame plate section322with mounting flanges324configured to secure closure latch assembly300to an edge portion of vehicle body11(FIG.1). As an alternative, power actuator310could be located remotely from closure latch assembly300but still be operatively arranged to rotate drive wheel314about axis320. Latch mechanism302is generally similar to latch mechanism30and is configured in this non-limiting arrangement embodiment as a single pawl/ratchet arrangement having ratchet40and pawl42. Ratchet40is supported in the latch housing for rotation about ratchet pivot post44between a series of distinct positions including a striker release position, a secondary striker capture position, and a primary striker capture position. Ratchet40is again configured to include primary latch shoulder48and secondary latch shoulder49. Ratchet biasing member, schematically indicated by arrow50, functions to normally bias ratchet40in a releasing direction (i.e. clockwise inFIG.29) toward its striker release position. Pawl42is supported in the latch housing for rotational movement about pawl pivot post52between a ratchet holding position and a ratchet releasing position. Pawl biasing member, schematically indicated by arrow54, functions to normally bias pawl42in an engaging direction (i.e. counterclockwise inFIG.29) toward its ratchet holding position. Pawl42includes pawl latch lug56and pawl release lug58.FIG.29shows ratchet40held in its primary striker capture position by pawl42being located in its ratchet holding position due to pawl latch lug56engaging primary latch shoulder48. Pawl42is shown schematically connected to release handle14via release cable18such that activation of release handle14functions to mechanically move pawl42from its ratchet holding position into its ratchet releasing position when manual release of latch mechanism302is desired. Drive mechanism312includes drive wheel314and an elongated coupling lever328. Drive wheel314is configured to include a cylindrical body segment330fixed to motor shaft318for rotation about axis320, a first or “latch release” lug332extending radially from body segment330, and a second or “latch cinch” lug334also extending radially from body segment330. Coupling lever328includes a first end segment336mounted via a coupling lever pivot pin338to latch cinch lug334, a second end segment340defining a coupler feature342, and an intermediate segment344defining a follower cam portion346and an actuation cam portion348which are disposed on opposite sides of a drive cam portion350. As will be detailed, the electric motor of power actuator310is operable, in response to control signals from latch controller37, to rotate drive wheel314between a first or “home” position and a second or “power release” position to provide the power release function. In addition, rotation of drive wheel314by the electric motor between its home position and a third or “power cinch” position provides the power cinch function. Spring-loaded lift mechanism306is generally shown inFIG.29to include a lift lever360and a lift lever spring362. Lift lever360includes a spring plate segment364and a striker plate segment366both of which are interconnected for common rotation about a lift lever pivot post368which, in this non-limiting embodiment, is commonly aligned with ratchet pivot post44. Lift lever spring362has a first spring end370secured to a stationary lug372extending from the latch housing and a second spring end374secured to a retention lug376formed on spring plate segment364. Lift lever spring362functions to normally bias lift lever360in a pop-up direction (i.e. clockwise inFIG.29). Striker plate segment366includes a striker lug378that is adapted to engage striker22. Latch cinch mechanism308is shown, in this non-limiting embodiment, to generally include a cinching lever380and a cinching pawl382. Cinching lever380is pivotally mounted to the latch housing via a cinching lever pivot post384which is also shown to be commonly aligned with ratchet pivot post44. A cinching lever biasing member, schematically shown by arrow386, functions to normally bias cinching lever380toward a first or “home” position. Cinching lever380includes a first drive post388extending into a drive slot390formed in cinching pawl382and a second drive post392configured to interact with coupler feature342on coupling lever328. Cinching pawl382is pivotably mounted to the latch housing via a cinching pawl pivot post394which is also shown commonly aligned with ratchet pivot post44. Cinching pawl382includes a cinching pawl drive lug395configured to be engageable with ratchet40. As will be hereinafter detailed,FIGS.30A-30B through34A-34Bprovide a series of sequential views of closure latch assembly300illustrating a dual-stage power release operation withFIGS.30A-30B through32A-32Bshowing a first stage or “primary latch” release operation and withFIGS.33A-33B through34A-34Bshowing a second stage or “safety latch” release operation. In addition,FIGS.35A through38include a series of sequential views illustrating initiation and completion of the power cinch operation. As noted, closure latch assembly300is equipped with a single power actuator310which functions, in coordination with drive mechanism312, to provide both the power release and the power cinch functions. FIGS.30A and30Billustrate closure latch assembly300operating in a primary latched mode for holding decklid12in its fully-closed position relative to body11of vehicle10. With closure latch assembly300in its primary latched mode, latch mechanism302is operating in a primary latched state with ratchet40located in its primary striker capture position and pawl42located in its ratchet holding position. Striker22is shown captured/retained within striker guide channel46of ratchet40such that striker22engages striker lug378on striker plate segment364so as to forcibly locate lift lever360in a first or “non-deployed” position, in opposition to the biasing load exerted thereon by lift lever spring362. With lift lever360held in its non-deployed position, lift mechanism306operates in a spring-loaded state. Latch cinch mechanism308is shown inFIGS.30A and30Boperating in an uncoupled state with cinching lever380located by cinching lever biasing member386in its home position. Note that cinching pawl382is also located in a first or “home” position. Finally, drive wheel314is shown located in its home position which, in turn, causes coupling lever328to be located in a first or “released” position, thereby defining a home operating state for drive mechanism312. With coupling lever328located in its released position, follower cam portion348rests against a mating arcuate surface396formed on body segment330and drive cam portion350engages latch release lug332. A coupling lever biasing member, schematically shown by arrow400, functions to bias coupling lever328toward its released position. As such, actuation cam portion346is displaced from engagement with pawl release lug58on pawl42and coupler feature342is displaced from engagement with second drive post392on cinching lever380. Thus, latch release mechanism304, defined by the relationship between actuation cam portion of coupling lever328and pawl release lug58on pawl42, establishes a non-actuated state. Likewise, latch cinch mechanism308is operating in an uncoupled state when cinching lever380is in its home position and coupling lever328is located in its released position. FIGS.31A and31Billustrate, in comparison toFIGS.30A and30B, respectively, initiation of the power release operation in response to latch controller receiving a power release signal. Specifically, the electric motor of power actuator310is actuated to cause drive wheel314to begin rotating in a first (i.e. counterclockwise) direction from its home position into its power release position (shown) for shifting drive mechanism312from its home state into a primary latched released state. In particular, such rotation of drive wheel314causes latch release lug332to drive coupling lever328from its released position into a second or “pawl release” position whereat actuation cam portion348engages pawl release lug58on pawl42and causes pawl42to move from its ratchet holding position into its ratchet releasing position, whereby pawl latch lug56is disengaged from primary latch shoulder48on ratchet40. Ratchet40is then driven by ratchet biasing member50from its primary striker capture position toward its secondary striker capture position. Concurrently, lift mechanism30is shifted from its spring-loaded state into a spring released state such that lift lever spring362drives lift lever360in a releasing (i.e. clockwise) direction from its non-deployed position toward a second or “deployed” position which causes striker lug378to engage striker22and begin to forcibly move decklid12from its fully-closed position toward its partially-closed pop-up position. Thus, latch release mechanism304has shifted from its non-actuated state into an actuated state which causes latch mechanism302to be shifted from its primary latched state into a primary unlatched state. FIGS.32A and32Billustrate, in comparison toFIGS.31A and31B, respectively, that ratchet40continues to rotate until it reaches its secondary striker capture position whereat blocker lug162on safety pawl142engages secondary latch shoulder49on ratchet40such that safety latch mechanism130is now operating in its safety latched state so as to define a secondary latched state for latch mechanism302. Note that in its secondary latched state, pawl latch lug56remains disengaged from latch shoulder48and pawl42is inhibited from returning to its ratchet holding position by engagement with an edge portion of ratchet40. The electric motor of power actuator310is then signaled to rotate drive wheel314in a second (i.e. clockwise) direction from its power release position back to its home position which, in turn, causes coupling lever328to return to its released position, thereby completing the first stage of the dual-stage power release operation. Safety pawl142is shown inFIG.32Blocated in its ratchet blocked position with its blocker lug162engaging secondary latch shoulder49on ratchet40. FIGS.33A and33Billustrate, in comparison toFIGS.32A and32B, respectively, rotation of drive wheel314in the first direction from its home position back into its power release position such that coupling lever328again is driven from its released position into its pawl released position. As such, actuation cam portion348of coupling lever328engages pawl release lug58on pawl42. Thus, pawl42is again moved into its ratchet releasing position in response to movement of coupling lever328from its released position to its pawl release position. Such movement of pawl42now causes corresponding movement of coupling link140due to engagement of pawl drive lug146with first end segment144of coupling link140. As previously described, such movement of coupling link140results in corresponding movement of safety pawl142from its ratchet blocked position into its ratchet unblocked position, whereby blocker lug162is released from secondary latch shoulder49on ratchet40. Accordingly, the safety unlatched state is established for safety latch mechanism130and an unlatched state is established for latch mechanism302upon completion of the second state of the dual-stage power release operation. Ratchet biasing member50is now permitted to drive ratchet40from its secondary striker capture position into its striker release position, thereby releasing striker22from ratchet40so as to permit subsequent manual movement of decklid12toward its fully-open position since striker22is no longer retained within guide channel46nor movement limited by safety hook segment132. Accordingly, closure latch assembly300is shifted from its secondary latched mode into its released mode. FIGS.34A and34Billustrate the electric motor of power actuator310rotating drive wheel314in the second direction back to its home position following completion of the second stage of the dual-stage power release operation. In summary,FIGS.30-34illustrates a first actuation of drive wheel314causes latch mechanism302to shift from its primary latched state into its unlatched state to permit movement of decklid from its fully-closed position into its partially-closed position, and a second actuation of drive wheel314causes latch mechanism302to shift from its secondary latched state into its unlatched state to permit subsequent movement of decklid12from its partially-closed position toward its fully-open position. Referring now toFIGS.35through38, the power cinch operation provided by closure latch assembly300will now be described in detail. In comparison toFIGS.34A and34Bwhich show closure latch assembly300operating in its released mode,FIGS.35A and35Billustrate that movement of decklid12from its fully-open position into its pop-up position (during a manual closing operation) causes striker22to engage and drive ratchet40(in opposition to ratchet biasing member50) from its striker release position into its secondary striker capture position. Once ratchet40is located in its secondary striker capture position, safety latch mechanism130shifts into its safety latched state with safety pawl142located in its ratchet blocked position. Note that drive mechanism312is operating in its home state with drive wheel314located in its home position and coupling lever328located in its released position. FIG.36illustrates initial rotation of drive wheel314by the electric motor in the second direction from its home position toward its power cinch position causes coupling lever328to move from its released position into an engaged position whereat coupler feature342engages second drive post392on cinching lever380. Coupler feature342is configured as a latch shoulder operable to engage second drive post392when coupler lever328is located in its engaged position. In view of this coupled interface between coupling lever328and cinching lever380, latch cinch mechanism308is now defined to be operating in its coupled state. FIG.37illustrates that continued rotation of drive wheel314by the electric motor from its engaged position into its power cinch position causes coupling lever328to be driven from its engaged position into a latch cinch position. Such movement of coupling lever328into its latch cinch position results in movement of cinching lever380from its home position (FIG.36) into a cinched position due to the coupled interface established between coupler feature342and second drive post392. Movement of cinching lever380from its engaged position into its cinched position causes first drive post388to engage an end of drive slot390in cinching pawl382and drive cinching pawl382from its home position into a ratchet cinched position. Since cinching pawl382is connected to ratchet40(via engagement with cinching pawl drive lug395), such movement of cinching pawl382into its ratchet cinched position results in corresponding movement of ratchet40from its secondary striker capture position into its primary striker capture position. Thus, latch mechanism302is shifted from its secondary latched state into its primary latched state and pawl42is permitted to return to its ratchet holding position with its latch lug56engaged with primary latch shoulder48on ratchet40. Such cinching movement of ratchet40also functions to shift lift mechanism306back into its spring-loaded state with lift lever360held in its non-deployed position. FIG.38illustrates that electric motor of power actuator310rotates drive wheel314in the first direction from its power cinch position (FIG.37) back to its home position at the conclusion of the power cinch operation. As seen, closure latch assembly300is operating in its primary latched mode with latch mechanism302in its primary latched state. Drive mechanism312is configured to utilize bi-directional rotation of drive wheel314to provide both the power release function and the power cinch function. This is in contrast to the uni-directional drive cam arrangement associated with closure latch assembly16. In addition, the configuration of drive wheel314and its operative connection to coupling lever328provide a generally pivotal-type movement of coupling lever328between its home and power release positions while also providing a generally translational-type movement of coupling lever328between its home and power cinch positions. Thus, a single power actuator310, in combination with drive mechanism312, provides closure latch assembly300with a compact packaging arrangement capable of controlling actuation of latch release mechanism302and latch cinch mechanism308. Now referring toFIGS.33A,36and37, there is provided a drive mechanism312for a closure latch assembly300for use in a motor vehicle having a closure member that is moveable between a fully-open position and a fully-closed position, the drive mechanism including a drive wheel314including a body segment330, and a coupling lever328pivotally mounted to the body segment330, the coupling lever328including a coupler feature342adapted to engage a first latch mechanism, an actuation cam adapted to engage a second latch mechanism, and a follower cam348adapted to engage the body segment. The driven rotation of the drive wheel in a first direction, illustratively shown inFIG.33Aas counterclockwise causes follower cam adapted to engage the body segment to move the actuation cam portion348tangentially, as represented by arc T, to engage the second latch mechanism, such as a pawl, and wherein a driven rotation of drive wheel314in a second direction causes follower cam348to disengage the body segment330to move the coupler feature342radially, as represented by arrow T, to engage the first latch mechanism, such as a cinch lever. In this manner, a drive mechanism312is provided that can actuate a first latch mechanism requiring a small input movement of actuation which may be provided by a tangential movement of the actuation cam, and that can also actuate a second latch mechanism requiring a larger and different input direction of movement of actuation which may be provided by a radial movement of the coupler feature to both radially move and outwardly push the second latch mechanism, for example with reference toFIGS.36and37, coupler feature342has move second drive post392radially outwardly, for example push, from a first radial position R1to a second greater radial position R2. Now referring toFIG.39, there is illustrated a method of operating a drive mechanism for a closure latch assembly1000, including the steps of driving a cam wheel in a first direction to cause a coupling lever pivotally mounted to the cam wheel to tangentially move to engage a first latch mechanism1002, and driving a cam wheel in a second direction to cause the coupling lever to radially move to engage a second latch mechanism1004. The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure. | 72,712 |
11859417 | DETAILED DESCRIPTION The car door1inFIG.1is shown in three positions2,3,4, the closed end position2, the intermediate position3and the open end position4. The car key5has different buttons, i.e. one button6to open the driver door, one button7for the trunk and one button8to close the car. The functions of this key can also be realized in a smartphone5′, a smart card, etc. When the button6is pushed the control unit of the locking device releases the closed end position2and starts the movement of the car door1into the latched intermediate position3. In the intermediate position3the car door1can be unlatched and pulled into the open end position4without a door handle. In improved versions the movements of the car door1arepartially or completely operated automatically by driving means. Also the intermediate position3can be unlatched automatically by a control unit, i.e. when the key button6is pushed again. In the described embodiment the access authorization is made by the key5or the smartphone5′ or the smartcard. A keyless entry is possible i.e. using a proximity sensor detecting andidentifying an authorized device the key5, the smartphone5′, the smartcard, etc. In this case the different doorpositions2,3,4can be associated to different, preferably configurable distances as shown inFIG.4. For example in the middle distance9the intermediate position3can be activated and in the near distance10the movement into the open end position4can be started. This movement can then be stopped by the user near by the door. On the other hand the movement from the open end position4or from the intermediate position3into the closed end position2can be started when the authorizing device or person is leaving the car12,especially the spaced distance11. This distance can also be a welcome distance in which the car gives signals when the user is nearing to the car12.1car door2closed end position3intermediate position4open end position5car key5′ smartphone6key button7key button8key button9middle distance10near distance11spaced distance12car | 2,055 |
11859418 | DESCRIPTION OF EMBODIMENTS Hereinafter, an embodiment of the present invention will be described, based on the drawings. As illustrated inFIG.1toFIG.3, an automobile door latch device1includes: a latch mechanism2configured to hold a door at a closing position; a manual releasing mechanism3that is able to perform a releasing operation for releasing the meshing of the latch mechanism2by a manual operating force; a locking mechanism4that is able to switch between a locked state in which the releasing operation by the manual releasing mechanism3is disabled and an unlocked state in which the releasing operation by the manual releasing mechanism3is enabled; and an electric releasing mechanism5that is able to release the meshing of the latch mechanism2by electromotive power. As illustrated inFIG.1, the latch mechanism2includes: a latch21pivotally supported in a body6fixed inside a door by a latch shaft24and configured to mesh with a striker (not illustrated) on a vehicle body side upon closing the door; a ratchet22pivotally supported in the body6by a ratchet shaft25and configured to engage with the latch21meshing with the striker to prevent the latch21from rotating and to hold the door at the closing position; and a ratchet lever23(seeFIG.2andFIG.3) rotatable integrally with the ratchet22. The ratchet22rotates on a ratchet shaft25in a releasing direction, that is, a clockwise direction inFIG.1, and thereby releasing the engagement with the latch21to make it possible to open the door. “Releasing the meshing” of “the latch mechanism2” used in the following descriptions means that the engagement of the ratchet22and the latch21is released, whereby the door can be opened. Note that the ratchet22and the ratchet lever23are formed separately in the present embodiment, but are not limited to this configuration, and the ratchet22and the ratchet lever23may be integrally formed. As illustrated inFIG.2andFIG.3, the manual releasing mechanism3includes an outside lever31configured to work in an interlocked manner with a mechanical operation of an outside handle (not illustrated) provided on the vehicle outer side of a door, and an inside lever32configured to work in an interlocked manner with a mechanical operation of an inside handle (not illustrated) provided on the vehicle inner side of a door. The outside lever31is pivotally supported in a housing7fixed to the body6by a pivot shaft71arranged in a front-rear direction and is configured to rotate on the pivot shaft71in a releasing direction (in a clockwise direction inFIG.2) while interlocking with a mechanical operation of the outside handle. When the locking mechanism4is in the unlocked state, a rotary motion of the outside lever31is transmitted to the ratchet22via the ratchet lever23as described below. When the locking mechanism4is in the locked state, a rotary motion of the outside lever31is not transmitted to the ratchet22as described below. The inside lever32is pivotally supported in the housing7by a pivot shaft72arranged in a right-left direction and is configured to rotate on the pivot shaft72in a clockwise direction inFIG.3while interlocking with a mechanical operation of the inside handle. A rotary motion of the inside lever32is directly transmitted to the outside lever31. Accordingly, when the locking mechanism4is in the unlocked state, a rotary motion of the inside handle is transmitted to the ratchet22, and in contrast, when the locking mechanism4is in the locked state, a rotary motion of the inside handle is not transmitted to the ratchet22. Note that a left side face of the housing7, the face facing the inside of a vehicle, is closed by a cover7aas illustrated inFIG.1. The locking mechanism4includes a locking lever41pivotally supported in the housing7by a pivot shaft73, a sub-lever42coupled to the locking lever41, a first active lever43pivotally supported in the housing7by a pivot shaft74, and a second active lever44pivotally supported on the same pivot shaft as the first active lever43. The locking lever41is rotatable in the front-rear direction on the pivot shaft73, and, for example, rotatable through a predetermined angle in a counterclockwise direction from an unlocked position to a locked position illustrated inFIG.3, and in a direction reverse to the counterclockwise direction by a rotation of a rotating cam52by power of a later-described motor51, and by a manual operating force of a key cylinder provided on the vehicle outer side of the door by using a key. When the locking lever41is arranged in the unlocked position, the locking mechanism4is in the unlocked state. In contrast, when the locking lever41is arranged in the locked position, the locking mechanism4is in the locked state. An input part41aprotruding rightward in a bar manner to face the outer side of the vehicle is provided in an upper portion of the locking lever41. A first acting part52band a second acting part52cof the rotating cam52, which will be later described, act on the input part41a. A key lever46pivotally supported in the housing7and configured to rotate on a rotating part46awhile being interlocked with a rotation of a key cylinder by using a key is coupled to an upper end of the locking lever41. The key lever46is coupled to the locking lever41via a sub-key-lever48pivotally supported below the key lever46. Thus, even in an emergency in which the meshing of the latch mechanism2cannot be released by power of the motor51due to a battery voltage drop, for example, the locking mechanism4can be switched from the locked state to the unlocked state and from the unlocked state to the locked state by a manual operating force by using a key. Note that, in the present embodiment, when the locking mechanism4is in the locked state, the opening of a door is made possible by power of the motor51, and hence, basically an operation of the locking mechanism4by using a key is not performed unless an emergency occurs. An upper portion of the sub-lever42is rotatably coupled to a lower portion of the locking lever41and slidably coupled in a vertical direction. A lower end of the sub-lever42is coupled to a coupling part31a, that is, an end of the outside lever31so as to be rotatable through a predetermined angle in the front-rear direction. Thus, when the locking lever41rotates from the unlocked position to the locked position or from the locked position to the unlocked position, the sub-lever42is interlocked with this rotation and thereby rotates on the coupling part31aserving as a rotation center through a predetermined angle in the counterclockwise direction from an unlocked position illustrated inFIG.3to a locked position, or from the locked position to the unlocked position. In the case where the locking lever41and the sub-lever42are each at the unlocked position, when the outside lever31rotates based on a mechanical operation of the outside handle or the inside handle, the sub-lever42moves straight upward from the unlocked position illustrated inFIG.3, so that a releasing part42aprovided in the sub-lever42comes into contact with an arm23aof the ratchet lever23from below. Thus, the ratchet lever23and the ratchet22rotate in a releasing direction to release the meshing of the latch mechanism2. In the case where the locking lever41and the sub-lever42are at their respective locked positions, even when the outside lever31rotates based on a mechanical operation of the outside handle or the inside handle, the sub-lever42is guided diagonally forward and upward by the locking lever41, and accordingly, the releasing part42aof the sub-lever42does not come into contact with the arm23aof the ratchet lever23. Thus, the ratchet lever23and the ratchet22do not rotate in the releasing direction, and therefore, the door cannot be opened by a mechanical operation of the outside handle or the inside handle. FIG.4is a perspective view of a main part;FIG.5is a perspective view of the main part seen from a direction different from the direction inFIG.4; andFIG.6toFIG.12are front views for describing operations of the main part. An approximately center portion of the first active lever43arranged in the vertical direction is pivotally supported in the housing7by the pivot shaft74, and also a coupling shaft43aprovided in an upper end of the first active lever43is rotatably and vertically movably coupled to a long hole41bprovided in the vertical direction in a lower portion of the locking lever41. Thus, the first active lever43rotates while following a rotation of the locking lever41, and, when the locking lever41is at the locked position, the first active lever43is elastically held at a locked position illustrated inFIG.6. When the locking lever41is at the unlocked position, as illustrated inFIG.11, the first active lever43rotates through a predetermined angle from the locked position in the clockwise direction to be elastically held at an unlocked position. The first active lever43is elastically held at the locked position or the unlocked position by an elastic force of a spring47configured to act on the first active lever43. A holding force of the spring47to elastically hold the first active lever43at each of the positions is transmitted also to the locking lever41. A rear end of the second active lever44is pivotally supported in the housing7by the pivot shaft74, and also biased in the counterclockwise direction by a spring45. When the locking lever41and the first active lever43are at their respective locked positions, a first protrusion44aprovided on the back side of the second active lever44comes into contact with a first stopper75provided in the housing7, at a locked position from the counterclockwise direction. When the first active lever43rotates from the locked position to the unlocked position, a protrusion43bprovided in the first active lever43comes into contact with the first protrusion44aof the second active lever44from the clockwise direction. Thus, the second active lever44rotates in the clockwise direction from a locked position through a predetermined angle against a biasing force of the spring45, and shifts to, for example, an unlocked position illustrated inFIG.11. An end44dof the second active lever44having moved to the unlocked position comes into contact with a second stopper78provided in the housing7. At an upper front end of the second active lever44, a second protrusion44band a stopper44ceach interacting with the rotating cam52of the electric releasing mechanism5are provided. When the second active lever44is at the locked position, the second protrusion44bis positioned apart from a rotation orbit of the rotating cam52. When the second active lever44rotates to the unlocked position, the second protrusion44benters the rotation orbit of the rotating cam52. Thus, when the second active lever44is in the locked position, an angle of rotation of the rotating cam52from the reference position in the clockwise direction (the normal direction) is not regulated, and when the second active lever44is in the unlocked position, the angle of rotation of the rotating cam52from the reference position in the clockwise direction is regulated to a predetermined angle. As illustrated inFIG.2andFIG.3, the electric releasing mechanism5includes: a motor51supported in the housing7; the rotating cam52including a worm wheel rotatable on a pivot shaft76in the normal and reverse directions, based on power of the motor51, by meshing with a worm gear51arotating integrally with a rotating shaft of the motor51; and an opening lever53rotatable on a pivot shaft77in the counterclockwise direction by a rotation of the rotating cam52in the clockwise direction (normal direction) from the reference position illustrated inFIG.6. When a sensor (not illustrated) detects an initial motion among mechanical operations of the outside handle, or when a locking operation of a user's mobile wireless operation switch and transmitter is performed, the motor51is driven in the normal direction of rotation. When an unlocking operation of the wireless operation switch and transmitter is performed, the motor51is driven in the reverse direction of rotation. Note that the detection of the sensor is effective only when an authentication device installed in an automobile has authenticated the wireless operation switch and transmitter. The rotating cam52is pivotally supported in the housing7by the pivot shaft76extending in the right-left direction, and is usually elastically held at, for example, a reference position illustrated inFIG.6(the reference position) by a biasing force of a spring54provided on the back side of the rotating cam52. The rotating cam52rotates from a reference position in the clockwise direction (normal direction) against a biasing force of the spring54by a normal rotation of the motor51. The rotating cam52rotates from the reference position in the counterclockwise direction (reverse direction) against a biasing force of the spring54by a reverse rotation of the motor51. After the rotation in the clockwise direction or the counterclockwise direction, when electric supply to the motor51is stopped, the rotating cam52rotates by a biasing force of the spring54, and returns to the reference position. The rotating cam52includes a cam52aconfigured to act on the opening lever53, a first acting part52band a second acting part52ceach configured to act on the locking lever41of the locking mechanism4, a third acting part52dconfigured to act on the first active lever43of the locking mechanism4, and a fourth acting part52eand a fifth acting part52feach configured to interact with the second active lever44. The opening lever53is pivotally supported in the housing7by the pivot shaft77arranged in the right-left direction, and includes a first arm53aextending forward to overlap with a rotation face of the rotating cam52, and a second arm53bextending diagonally backward and downward and configured to act on the ratchet lever23. The cam52aof the rotating cam52has a semicircle shape protruding leftward on a rotation surface on the front side of the rotating cam52, and, when the rotating cam52rotates from the reference position in the clockwise direction against the biasing force of the spring54, an arc-shaped surface of the cam52acomes into contact with the first arm53aof the opening lever53from above, and thereby presses down the first arm53aand acts to cause the opening lever53to rotate from the reference position in the counterclockwise direction. When the opening lever53rotates from the reference position in the counterclockwise direction, the second arm53bcomes into contact with the arm23aof the ratchet lever23from below, so that, regardless of a state of the locking mechanism4, the opening lever53rotates the ratchet22in the releasing direction to release the meshing of the latch mechanism2and thereby make a door opening operation possible (a releasing operation of the opening lever53). The first acting part52bof the rotating cam52is provided so as to be positioned slightly apart from the second acting part52cin the counterclockwise direction and protrude outward longer from the outer periphery of the rotating cam52than the second acting part52c. When the rotating cam52rotates from the reference position in the clockwise direction against the biasing force of the spring54, the first acting part52bcomes into contact from ahead with the input part41aof the locking lever41at the locked position, so that the rotating cam52acts on the locking lever41to shift the locking lever41from the locked position to the unlocked position. In this case, on or immediately after shifting the locking lever41to the unlocked position, the rotating cam52is regulated in rotation in the clockwise direction and stops at a release position illustrated inFIG.8, and electric supply to the motor51is stopped, so that the rotating cam52rotates from the release position in the counterclockwise direction by a biasing force of the spring54, and returns to the reference position. When the rotating cam52returns from the release position to the reference position by the biasing force of the spring54, the second acting part52ccomes into contact with the input part41aof the locking lever41at the unlocked position from the counterclockwise direction, so that the rotating cam52acts on the locking lever41to shift the locking lever41from the unlocked position to the locked position. When the rotating cam52is at the reference position and the first active lever43is at the locked position, the third acting part52dfaces a first engaging part43cof the first active lever43as illustrated inFIG.6. When the rotating cam52is at the reference position and the first active lever43is at the unlocked position, the third acting part52dfaces a second engaging part43dof the first active lever43as illustrated inFIG.11. When the first active lever43is at the locked position and the rotating cam52rotates through a predetermined angle from the reference position in the counterclockwise direction by power of the motor51, the third acting part52dcomes into contact with the first engaging part43cof the first active lever43, so that the first active lever43is shifted from the locked position to the unlocked position. When the first active lever43is at the unlocked position and the rotating cam52rotates from the reference position in the clockwise direction by power of the motor51, the third acting part52dcomes into contact with the second engaging part43dof the first active lever43, so that the first active lever43is shifted from the unlocked position to the locked position. Note that, when the locking mechanism4is in the unlocked state, an angle of rotation of the rotating cam52from the reference position in the clockwise direction is regulated by the second active lever44so as to be smaller than in a case in which the locking mechanism4is in the locked state, as described below, and hence, the releasing operation of the opening lever53is not performed with the rotation of the rotating cam52in the clockwise direction. In the case where the second active lever44is at the unlocked position, the fourth acting part52eof the rotating cam52comes into contact with the stopper44cof the second active lever44at the time when the rotating cam52rotates through a predetermined angle from the reference position in the clockwise direction against a biasing force of the spring54by power of the motor51, whereby the angle of rotation of the rotating cam52in the clockwise direction is regulated so as to be smaller than in the case in which the locking mechanism4is in the locked state. In the case where the locking mechanism4is in the unlocked state and the second active lever44is in the unlocked position, when the rotating cam52rotates from the reference position in the clockwise direction by power of the motor51, the fifth acting part52fchanges its own position so as to be engageable with the second protrusion44bof the second active lever44, before the fourth acting part52ecomes into contact with the stopper44cof the second active lever44and the third acting part52dcomes into contact with the second engaging part43dof the first active lever43, so that the fifth acting part52fprevents the second active lever44from rotating in the counterclockwise direction, that is, from rotating toward the locked position. Thus, the second active lever44is held at the unlocked position, until all the constituents of the locking mechanism4except the second active lever44shift to their respective locked positions, and the angle of rotation of the rotating cam52from the reference position in the counterclockwise direction is surely regulated to be a predetermined angle. Next, a description will be given of an action of the automobile door latch device1. <Case where Locking Mechanism4is in Locked State and Rotating Cam52Rotates from Reference Position in Clockwise Direction> FIG.6illustrates a state in which the locking mechanism4is in the locked state and the rotating cam52is in a reference position.FIG.7illustrates a state in which the rotating cam52is in the middle of rotating from the reference position in the clockwise direction by power of the motor51.FIG.8illustrates a state in which the rotating cam52has rotated from the reference position in the clockwise direction and stopped at a release position.FIG.9illustrates a state in which the rotating cam52is in the middle of returning from the release position to the reference position. When the rotating cam52rotates in the clockwise direction from the reference position illustrated inFIG.6, an arc-shaped surface of the cam52acomes into contact with the first arm53aof the opening lever53from above with the rotation of the rotating cam52, so that the opening lever53is rotated in the counterclockwise direction, that is, a releasing direction. Then, as illustrated inFIG.7, when the rotating cam52rotates in the clockwise direction from the reference position through approximately 120 degrees, the opening lever53rotates to a final position in the releasing direction, and releases the meshing of the latch mechanism2via the ratchet lever23to make the opening of a door possible. When the rotating cam52further rotates in the clockwise direction from a position illustrated inFIG.7, the first acting part52bcomes into contact with the input part41aof the locking lever41, so that, as illustrated inFIG.8, the locking lever41is rotated from the locked position to the unlocked position and the rotating cam52stops at the release position. In this case, with the rotation of the locking lever41from the locked position to the unlocked position, the first active lever43and the second active lever44also rotate from their respective locked positions to their respective unlocked positions, but, the rotations of the first active lever43and the second active lever44do not affect other constituents. In the present embodiment, when the rotating cam52rotates from the reference position in the clockwise direction, the meshing of the latch mechanism2is released first, and subsequently the locking mechanism4is switched from the locked state to the unlocked state. However, instead, the releasing of the meshing of the latch mechanism2and the switching of the locking mechanism4from the locked state to the unlocked state may be simultaneously performed, or alternatively, the switching of the locking mechanism4from the locked state to the unlocked state may be performed prior to the releasing of the meshing of the latch mechanism2. When the rotating cam52stops at the release position illustrated inFIG.8, electric supply to the motor51is stopped. Thus, the rotating cam52rotates from the release position toward the reference position in the counterclockwise direction by a biasing force of the spring54. Then, as illustrated inFIG.9, when the rotating cam52slightly rotates from the release position toward the reference position, the second acting part52cof the rotating cam52comes into contact with the input part41aof the locking lever41from the counterclockwise direction, so that the locking lever41is rotated to the locked position again. Subsequently, the rotating cam52further rotates in the counterclockwise direction by a biasing force of the spring54, and returns to the reference position illustrated inFIG.6and stops. To sum up the above-described operations, in the case where the locking mechanism4is in the locked state and the rotating cam52rotates from the reference position in the clockwise direction by power of the motor51, the rotation of the rotating cam52from the reference position in the clockwise direction allows the opening lever53to perform the release operation to make a door opening operation possible, and, at the same time, allows the locking mechanism4in the locked state to be once switched to the unlocked state. Then, with the return of the rotating cam52to the reference position by a biasing force of the spring54, the locking mechanism4having been switched to the unlocked state is switched to the locked state again. As described above, when a door is opened by power of the motor51, the locking mechanism4, which is not usually used, is switched. Thus, hardening of a grease or generation of rust on a movable portion of the locking mechanism4due to disuse of the locking mechanism4for a long time can be prevented. Thus, in an emergency, the locking mechanism4can be surely switched from a locked position to an unlocked position or from the unlocked position to the locked position. <Case where Locking Mechanism4is in Locked State and Rotating Cam52Rotates from Reference Position in Counterclockwise Direction> When the rotating cam52in a state illustrated inFIG.6rotates from the reference position in the counterclockwise direction by power of the motor51, the third acting part52dengages with the first engaging part43cof the first active lever43as illustrated inFIG.10, so that the first active lever43is rotated from the locked position to the unlocked position. Then, when electric supply to the motor51is stopped after the first active lever43is rotated to the unlocked position, the rotating cam52is rotated in the clockwise direction by a biasing force of the spring54from a position at which the first active lever43is rotated to the unlocked position, and returns to the reference position as illustrated inFIG.11. As described above, in the case where the rotating cam52is rotated from the reference position in the counterclockwise direction by power of the motor51while the locking mechanism4is in the locked state, the locking mechanism4can be independently switched from the locked state to the unlocked state. <Case where Locking Mechanism4is in Unlocked State and Rotating Cam52Rotates from Reference Position in Clockwise Direction> When the rotating cam52in a state illustrated inFIG.11rotates from the reference position in the clockwise direction, the fifth acting part52fimmediately slips into the back side of the stopper44cof the second active lever44to prevent the second active lever44from rotating from the unlocked position to the locked position. In this state, when the rotating cam52further rotates in the clockwise direction, the third acting part52dcomes into contact with the second engaging part43dof the first active lever43as illustrated inFIG.12, so that the first active lever43is rotated from the unlocked position to the locked position. Immediately after this rotation (a position after the rotating cam52rotates at approximately 30 degrees from the reference position in the clockwise direction), the fourth acting part52ecomes into contact with the stopper44cof the second active lever44from the clockwise direction, so that the rotating cam52stops in a position of the contact. Thus, in the case where the locking mechanism4is in the unlocked state, an angle of rotation of the rotating cam52from the reference position in the clockwise direction is regulated so as to be smaller than an angle of rotation for releasing the meshing of the latch mechanism2by the releasing operation of the opening lever53while the locking mechanism4is in the locked state. Then, when the rotating cam52stops rotation in the clockwise direction, electric supply to the motor51is stopped. Thus, the rotating cam52rotates in the counterclockwise direction from the stop position by a biasing force of the spring54, and returns to the reference position. When the rotating cam52returns to the reference position, the engagement relation between the fifth acting part52fof the rotating cam52and the second protrusion44bof the second active lever44is canceled. Thus, the first active lever43has already switched to the locked position, and accordingly, the second active lever44returns to the locked position by a biasing force of the spring45and enters a state illustrated inFIG.6. As described above, in the case where the rotating cam52is rotated from the reference position in the clockwise direction by power of the motor51while the locking mechanism4is in the unlocked state, the locking mechanism4can be independently switched from the unlocked state to the locked state. REFERENCE SIGNS LIST 1automobile door latch device2latch mechanism21latch22ratchet23ratchet lever23aarm24latch shaft25ratchet shaft3manual releasing mechanism31outside lever31acoupling part32inside lever4locking mechanism41locking lever41ainput part41blong hole42sub-lever42areleasing part43first active lever43acoupling shaft43bprotrusion43cfirst engaging part43dsecond engaging part44second active lever44afirst protrusion44bsecond protrusion44cstopper44dend45spring46key lever46arotating part47spring48sub-key-lever5electric releasing mechanism51motor51aworm gear52rotating cam52acam52bfirst acting part52csecond acting part52dthird acting part52efourth acting part52ffifth acting part53opening lever53afirst arm53bsecond arm54spring6body7housing7acover71,72,73,74pivot shaft75first stopper76,77pivot shaft78second stopper | 29,022 |
11859419 | DETAILED DESCRIPTION The present disclosure relates to the Chinese patent application no. 201680060437.1, entitled “Door handle for vehicle” and filed by the applicant on Oct. 20, 2016, and the Chinese patent application no. 201711423248.9, entitled “Hidden type handle assembly” and filed by the applicant on Dec. 25, 2017, which are incorporated herein by reference in their entirety. Particular embodiments of the present disclosure are described below with reference to the accompanying drawings which constitute part of this description. It is to be understood that although the terms indicating orientations, such as “front”, “rear”, “upper”, “lower”, “left”, “right”, “inner”, “outer” “top”, “bottom”, “obverse” and “reverse”, are used in the present disclosure to describe structural parts and elements in various examples of the present disclosure, these terms are used herein only for ease of illustration and are determined based on the exemplary orientations as shown in the accompanying drawings. Since the embodiments disclosed in the present disclosure can be arranged in different orientations, these terms indicating directions are only illustrative and should not be considered as limitations. If possible, the same or similar reference numerals used in the present disclosure refer to the same or similar components. In the following description, unless otherwise specified, the side facing the outside of the vehicle door is the outer side, and the side facing the inside of the vehicle door is the inner side. FIGS.1A-1Cshow structural views of a handle system100according to one embodiment of the present disclosure, whereinFIGS.1A and1Bshow the overall structures of the handle system100from different perspectives of a handle body, andFIG.1Cshows an exploded view of the handle system100. As shown inFIGS.1A-1C, the handle system100comprises a handle body101, a touch sensing device105and a controller110. The handle body101is provided with an inner-side grip portion122and an outer-side grip portion123connected to the inner-side grip portion122, wherein the inner-side grip portion122and the outer-side grip portion123respectively have an inner-side surface102and an outer-side surface103for touch by a user. A mounting structure151is provided on the inner-side grip portion122, and the handle body101is mounted on the vehicle door through the mounting structure151. The handle body101can be driven to a retracted position or a deployed position, and can rotate relative to the vehicle door about a shaft152provided through the mounting structure151. A mounting cavity133is provided between the inner-side grip portion122and the outer-side grip portion123for accommodating the touch sensing device105. The touch sensing device105is mounted in the mounting cavity133of the handle body101, for example, by means of gluing or clamping. The touch sensing device105is connected to the controller110and a power source (not shown), for example via one or more wires161. The controller110is a door control unit (DCU) that can be provided separately, integrated in the handle body101, or integrated in a central control system of a vehicle. The touch sensing device105comprises one or more sensing circuits. The one or more sensing circuits comprise a touch sensing region that enables the touch sensing device105to generate a corresponding sensing signal in response to a touch action on a surface (e.g. an inner-side surface102or an outer-side surface103) of the handle body101. In the present disclosure, the touch action refers to an action that can be sensed by the touch sensing device105such that the touch sensing device105generates a sensing signal. According to the characteristics of different touch sensing devices105, the touch action may be different. For example, for some touch sensing devices105, it is only necessary to lightly touch the surface of the handle body101(e.g. the outer-side surface103or the inner-side surface102) by hand; and for some touch sensing devices105, it is necessary to apply a certain pressure to the surface (e.g. the outer-side surface103or the inner-side surface102) of the handle body101so as to be sensed by the sensing circuits. The touch action comprises touch-slide, that is, touching and sliding. In the present disclosure, the touch sensing device105may be a touch type sensing circuit, that is, generating a sensing signal in response to a touch. The touch sensing device105may also be a touch-slide type sensing circuit, that is, generating a sensing signal in response to a touch-slide. In some embodiments, the touch sensing region of the touch sensing device105is configured to face the outer-side surface103and/or the inner-side surface102of the handle body101, and the area of the touch sensing region is set to be about 90% of the area of the outer-side surface103or the inner-side surface102. It needs to be noted that, although the touch sensing device105is arranged between the inner-side grip portion122and the outer-side grip portion123of the handle body in the embodiment shown inFIGS.1A-1C, the touch sensing device105may also be configured to be embedded in the inner-side grip portion122and/or the outer-side grip portion123, or configured to be closely adhered to the outer-side surface103and/or the inner-side surface102, as long as a touch action of the user can be sensed. The controller110is capable of generating a control signal according to the sensing signal, and driving the handle body101to deploy or retract, and performing activation, locking or other control operations on the vehicle according to the control signal. When the vehicle is in a stopped state, the controller110may perform information interaction through a system such as a PEPS, NFC, or Bluetooth configured in the vehicle, so as to receive a sensing signal and activate the vehicle. The handle body101is further provided with a position sensor(s) (not shown in the figures) for detecting the positions of the handle body101and sending the detected position information to the controller110. FIGS.2A-2Cshow simplified views of the handle body101inFIG.1Aat different positions, which respectively show that the handle body101is at a retracted position, a deployed position and a release position relative to an outer surface204of the vehicle door. As shown inFIG.2A, the handle body101is at the retracted position. When the handle body is at the retracted position, the outer-side surface103of the handle body101is flush with the outer surface204of the vehicle door, and only the outer-side surface103of the handle body101is accessible from the outside of the vehicle door. At this time, if the user touches or slidably touches the outer-side surface103of the handle body101, the touch sensing device105can be triggered to enable the handle body101to deploy. As shown inFIG.2B, in the state of the handle body shown inFIG.2A, after the outer-side surface103of the handle body101is touched or slidably touched, the handle body101can be driven out of the outer surface204of the vehicle door to be at the deployed position, such that the inner-side surface102of the handle body101is exposed. At this time, the user can simultaneously touch the inner-side surface102and the outer-side surface103of the handle body101by hand. As shown inFIG.2C, in the state of the handle body shown inFIG.2B, the user rotates the handle body101outwardly by hand so that the handle body101is at the release position. At this time, if the user releases the handle body101, the handle body101can automatically return to the deployed position shown inFIG.2Bby means of a reset structure (e.g. a reset spring). Moreover, by touching or slidably touching the inner-side surface102and/or the outer-side surface103of the handle body101again, the touch sensing device105can be triggered again so that the handle body101can return back to the retracted position ofFIG.2A. When the handle body101is at the release position, the vehicle door can be opened by pulling the handle body101. FIGS.3A and3Bshow two embodiments of the operation flow for controlling the deploying and retracting of the handle body according to the present disclosure.FIG.3Ais an operation flow chart illustrating indicating and controlling the deploying and retracting of the handle body by using two sensing circuits; andFIG.3Bis an operation flow chart illustrating indicating and controlling the deploying and retracting of the handle body by using one sensing circuit. In the embodiment as shown inFIG.3A, two sensing circuits, that is, an outer-side sensing circuit311and an inner-side sensing circuit312, are employed or used. The outer-side sensing circuit311and the inner-side sensing circuit312are respectively arranged proximate to the outer-side surface103and the inner-side surface102of the handle body101. The outer-side sensing circuit311and the inner-side sensing circuit312are capable of respectively generating an outer-side sensing signal and an inner-side sensing signal in response to a touch on the outer-side surface103and a touch on the inner-side surface102of the handle body101. The operations of indicating and controlling the deploying and retracting of the handle body101by the two sensing circuits311and312comprise four steps as follows: Step I: when the handle body101is at the retracted position (state I) and the vehicle door is in a closed state, if the vehicle door needs to be opened, the user touches the outer-side surface103of the handle body101by hand to trigger the outer-side sensing circuit311, and then the operation turns to step II. Step II: in response to the touch on the outer-side surface103in step I, the outer-side sensing circuit311generates an outer-side sensing signal, such that the controller110activates the vehicle according to the outer-side sensing signal and controls the handle body101to be driven to the deployed position (state II-1). Activating a vehicle refers to changing the state of the vehicle from an unmanipulable state to a manipulable state, for example, when the vehicle is in a non-activated state, the vehicle door is locked and cannot be opened, and the vehicle door can be opened when the vehicle is in an activated state. When the handle body101is at the deployed position, the user can rotate or pull the handle body101by holding the same by hand, such that the handle body101reaches the release position (state II-2) to allow to open the vehicle door. During the process of the user rotating or pulling the handle body101to the release position by holding the same by hand, the outer-side surface103and the inner-side surface102of the handle body101are simultaneously touched, such that the outer-side sensing circuit311and the inner-side sensing circuit312respectively generate an outer-side sensing signal and an inner-side sensing signal. Step III: the user releases the handle body101, causing the handle body101to be automatically returned to the deployed position by the reset device (e.g. the reset spring) (state III). After the user releases the handle body101, neither the outer-side surface103nor the inner-side surface102of the handle body101is touched any more, such that both of the outer-side sensing signal and the inner-side sensing signal cease. In step IV, the controller110controls the retracting of the handle body101and locks the vehicle door according to an indication that both of the outer-side sensing signal and the inner-side sensing signal cease, and the handle body101returns to the retracted position (state IV). In some embodiments, the controller110can also control the retracting of the handle body and lock the vehicle door after both of the outer-side sensing signal and the inner-side sensing signal cease for a period of time (e.g. 3 to 5 seconds). In some embodiments, if the outer-side sensing circuit311is triggered again when the handle body101is at the deployed position, the action of deploying the handle may still be performed, but since the handle body101has been deployed, the handle body101remains in the deployed position. In the embodiment as shown inFIG.3B, one sensing circuit, that is, a touch-slide type sensing circuit313, is employed or used. The touch-slide type sensing circuit313is arranged proximate to the outer-side surface103of the handle body101. The touch-slide type sensing circuit313is capable of generating a first-direction touch-slide sensing signal in responsive to a sliding touch action on the outer-side surface103of the handle body101in a first direction and a second-direction touch-slide sensing signal in responsive to a sliding touch action on the outer-side surface103of the handle body101in a different second direction. The operations of indicating and controlling the deploying and retracting of the handle body101by one touch-slide type sensing circuit313comprise four steps as follows: Step I: when the handle body101is at the retracted position (state I) and the vehicle door is in a closed state, if the vehicle door needs to be opened, the outer-side surface103of the handle body101is slidably touched in the first direction by hand. Step II: in response to the sliding touch on the outer-side surface103in the first direction in step I, the touch-slide type sensing circuit313generates a first-direction touch-slide sensing signal, such that the controller110activates the vehicle according to the first-direction touch-slide sensing signal and controls the handle body101to be driven to the deployed position (state II-1). When the handle body101is at the deployed position, the user can rotate or pull the handle body101by holding the same by hand, such that the handle body101reaches the release position (state II-2) to allow to open the vehicle door. Step III: the handle body101is released, causing the handle body101to be automatically returned to the deployed position by the reset device (e.g. the reset spring) (state III). After that, if the outer-side surface103of the handle body101is slidably touched in the second direction, the touch-slide type sensing circuit313can generate a second-direction touch-slide sensing signal. Step IV: the controller110, according to the second-direction touch-slide sensing signal, locks the vehicle door and controls the handle body101to be driven back to the retracted position (state IV). In some embodiments, the controller110can also control the retracting of the handle body101and lock the vehicle door after receiving the second-direction touch-slide sensing signal for a period of time (e.g. 3 to 5 seconds). In this embodiment, the first direction is different from the second direction, for example, the first direction may be from left to right, while the second direction may be from right to left; or the first direction may be clockwise, while the second direction may be counter-clockwise. Moreover, the sliding touch in the first direction and the sliding touch in the second direction may comprise various motion trajectories, such as linear motion, curvilinear motion and other more complex motion trajectories. FIG.4Ais a block diagram illustrating one embodiment of a control system400that implements the operation flow of controlling deploying and retracting of the handle body as shown inFIG.3A.FIG.4Bis a block diagram illustrating one embodiment of a control system470that implements the operation flow of controlling deploying and retracting of the handle body as shown inFIG.3B. As shown inFIG.4A, the control system400comprises the touch sensing device105, the controller110and a handle driving device430, wherein the touch sensing device105, the controller110and the handle driving device430are communicatively connected in sequence. The touch sensing device105comprises the outer-side sensing circuit311and the inner-side sensing circuit312that are respectively arranged proximate to the outer-side surface103and the inner-side surface102of the handle body101. When the outer-side surface103of the handle body101is touched, the outer-side sensing circuit311generates an outer-side sensing signal, and when the inner-side surface102of the handle body101is touched, the inner-side sensing circuit312generates an inner-side sensing signal. The outer-side sensing circuit311and the inner-side sensing circuit312are communicatively connected to the controller110via connections441and442, respectively, so as to send the generated sensing signals to the controller110. The controller110is communicatively connected to the handle driving device430via a connection450to send a first control signal and a second control signal to the handle driving device430. The handle driving device430is connected to the handle body101, and drives the handle body101to deploy according to the first control signal or drives the handle body101to retract according to the second control signal. The handle driving device430may comprise a motor, an electric motor or the like for providing driving force, and can be controlled by the controller110to mechanically or electromagnetically drive the handle body101to perform a corresponding action. The working process of the control system400shown inFIG.4Ais as follows: When the outer-side surface103of the handle body101is touched, the outer-side sensing circuit311generates an outer-side sensing signal, and when the inner-side surface102of the handle body101is touched, the inner-side sensing circuit312generates an inner-side sensing signal. After receiving the outer-side sensing signal and/or the inner-side sensing signal, the controller110generates a corresponding control signal according to a preset control logic or program. For example, when only the outer-side sensing signal is received, the controller110generates a first control signal indicating the deploying of the handle, and performs an operation of activating the vehicle according to the preset control logic or program; and when the received outer-side sensing signal and inner-side sensing signal both cease, the controller110generates a second control signal indicating the retracting of the handle, and performs an operation of locking the vehicle door according to the preset control logic or program. In some embodiments, the controller110can also generate the second control signal indicating the retracting of the handle, and perform an operation of locking the vehicle door according to the preset control logic or program after both of the outer-side sensing signal and the inner-side sensing signal cease for a period of time (e.g. 3 to 5 seconds). As shown inFIG.4B, the control system470comprises the touch sensing device105, the controller110and the handle driving device430, wherein the touch sensing device105, the controller110and the handle driving device430are communicatively connected in sequence. The touch sensing device105comprises the touch-slide type sensing circuit313, the touch-slide type sensing circuit313being arranged proximate to the outer-side surface103of the handle body101, wherein the touch-slide type sensing circuit313is communicatively connected to the controller110via a connection443to send the generated sensing signals to the controller110. The controller110is communicatively connected to the handle driving device430via the connection450to send the first-direction control signal and the second-direction control signal to the handle driving device430. The handle driving device430is connected to the handle body101, and drives the handle body101to deploy according to the first-direction control signal or drives the handle body101to retract according to the second-direction control signal. The working process of the control system470shown inFIG.4Bis as follows: When the outer-side surface103of the handle body101is slidably touched in the first direction, the touch-slide type sensing circuit313generates a first-direction touch-slide sensing signal according to the change of the touch positions, and sends the signal to the controller110; and when the outer-side surface103of the handle body101is slidably touched in the second direction, the touch-slide type sensing circuit313generates a second-direction touch-slide sensing signal according to the change of the touch positions, and sends the signal to the controller110. After receiving the first-direction touch-slide sensing signal or the second-direction touch-slide sensing signal from the touch-slide type sensing circuit313, the controller110generates a corresponding control signal according to a preset control logic or program. For example, when the first-direction touch-slide sensing signal is received, the controller110generates the first-direction control signal indicating the deploying of the handle, and performs an operation of activating the vehicle according to the preset control logic or program; and when the second-direction touch-slide sensing signal is received, the controller110generates the second-direction control signal indicating the retracting of the handle, and performs an operation of locking the vehicle door according to the preset control logic or program. In some embodiments, the controller110can also generate the second-direction control signal indicating the retracting of the handle, and perform the operation of locking the vehicle door according to the preset control logic or program after receiving the second-direction touch-slide sensing signal for a period of time (e.g. 3 to 5 seconds). FIG.5Ais a block diagram illustrating another embodiment of the control system400that implements the operation flow of controlling deploying and retracting of the handle body shown inFIG.3A.FIG.5Bis a block diagram illustrating another embodiment of the control system470that implements the operation flow of controlling deploying and retracting of the handle body shown inFIG.3B. The embodiments shown inFIGS.5A and5Bare respectively similar to the embodiments shown inFIGS.4A and4B, except that filter circuits are further provided in the embodiments shown inFIGS.5A and5B. As shown inFIG.5A, the touch sensing device105further comprises a first filter circuit511and a second filter circuit512, wherein the first filter circuit511is communicatively connected between the outer-side sensing circuit311and the controller110, and the second filter circuit512is communicatively connected between the inner-side sensing circuit312and the controller110. The first filter circuit511and the second filter circuit512can respectively receive the outer-side sensing signal generated by the outer-side sensing circuit311and the inner-side sensing signal generated by the inner-side sensing circuit312, and can perform filter processing on the received signals and then send the filter-processed sensing signals to the controller110via the connections441and442. The first filter circuit511and the second filter circuit512can filter out, from the outer-side sensing signal and the inner-side sensing signal, interference clutters and noises generated by other devices, thereby making the touch sensing more precise. In some embodiments, the first filter circuit511and the second filter circuit512can be filter capacitors. As shown inFIG.5B, the touch sensing device105further comprises a third filter circuit513, wherein the third filter circuit513is communicatively connected between the touch-slide type sensing circuit313and the controller110. The third filter circuit513can receive the touch-slide sensing signals generated by the touch-slide type sensing circuit313, and can perform filter processing on the received signals and then send the filter-processed sensing signals to the controller110via the connection443. The third filter circuit513can filter out, from the sensing signals, interference clutters and noises generated by other devices, thereby making the touch sensing more precise. In some embodiments, the filter circuits can be filter capacitors. FIG.6Ais a block diagram illustrating functional modules according to one embodiment of the touch sensing device105ofFIG.4A/5A.FIG.6Bis a block diagram illustrating functional modules according to one embodiment of the touch sensing device105ofFIG.4B/5B. As shown inFIG.6A, the touch sensing device105comprises the outer-side sensing circuit311and the inner-side sensing circuit312. The outer-side sensing circuit311comprises a first capacitive sensor610, a first measurement circuit611, a first comparison circuit612and a first processor613connected in sequence. The inner-side sensing circuit312comprises a second capacitive sensor620, a second measurement circuit621, a second comparison circuit622and a second processor623connected in sequence. In some embodiments, the first capacitive sensor610/the second capacitive sensor620comprises two parallel electrode plates separated by an insulating medium, and there is a certain distance between the two electrode plates. In response to a touch action of a hand, the distance between the two electrode plates of the first capacitive sensor610/the second capacitive sensor620changes, such that the capacitance of the first capacitive sensor610/the second capacitive sensor620changes. In some other embodiments, the first capacitive sensor610/the second capacitive sensor620comprises a touch electrode. Since human body tissues are filled with conductive electrolyte, a human body (e.g. a finger) will form a coupling capacitor with the first capacitive sensor610/the second capacitive sensor620when contacting or approaching the touch electrode, such that the capacitance of the first capacitive sensor610/the second capacitive sensor620is increased. In some embodiments, the first measurement circuit611/the second measurement circuit621is configured for converting the capacitance of the first capacitive sensor610/the second capacitive sensor620and its change value into a corresponding voltage, current or frequency signal, thereby facilitating detection, calculation, etc. In some embodiments, the first measurement circuit611/the second measurement circuit621may comprise an operational amplifier type circuit, and the first capacitive sensor610/the second capacitive sensor620is connected to the operational amplifier type circuit. An output voltage of the operational amplifier type circuit is proportional to the capacitance of the first capacitive sensor610/the second capacitive sensor620. Therefore, the first measurement circuit611/the second measurement circuit621converts, by a change in a voltage value at an output end of the operational amplifier type circuit, a change in capacitance of the first capacitive sensor610/the second capacitive sensor620into a measured voltage signal for output. In the embodiment where the first capacitive sensor610/the second capacitive sensor620comprises two parallel electrode plates, the relationship between the output voltage of the operational amplifier type circuit and the distance between the electrode plates of the first capacitive sensor610/the second capacitive sensor620is linear. In some embodiments, the first comparison circuit612/the second comparison circuit622can be a voltage comparator. One input end of the first comparison circuit612/the second comparison circuit622receives the measured voltage signal output by the first measurement circuit611/the second measurement circuit621, and the other input end thereof receives a preset threshold voltage; and an output end of the first comparison circuit612/the second comparison circuit622is connected to the first processor613/the second processor623. The first comparison circuit612/the second comparison circuit622compares the measured voltage signal obtained from the first measurement circuit611/the second measurement circuit621with a preset first threshold voltage signal/second threshold voltage signal, and if the measured voltage signal exceeds the first threshold voltage signal/the second threshold voltage signal, a high level signal is output to the first processor613/the second processor623(or if the measured voltage signal exceeds the first threshold voltage signal/the second threshold voltage signal, a low level signal is output). If the measured voltage signal does not exceed the first threshold voltage signal/the second threshold voltage signal, a low level signal is output to the first processor613/the second processor623(or if the measured voltage signal does not exceed the first threshold voltage signal/the second threshold voltage signal, a high level signal is output). By means of the threshold voltage signal preset in the first comparison circuit612/the second comparison circuit622, it is possible to filter out a capacitance value change that is caused due to other items accidentally triggering the sensing circuit and is smaller than a capacitance value change caused by finger touching, thereby making the touch sensing more precise. For example, when other items accidentally triggering the sensing circuit results in a small capacitance value of the first capacitive sensor610/the second capacitive sensor620, the measured voltage signal does not exceed the threshold voltage signal, and thus a low level signal is output to the first processor613/the second processor623, i.e. no valid signal output is caused. In some embodiments, the first processor613/the second processor623comprises internally integrated control logic and analog-to-digital converter. The first processor613/the second processor623receives a high level signal output by the first comparison circuit612/the second comparison circuit622, so that the internally integrated control logic and analog-to-digital converter thereof convert the high level signal into a digital signal for output to the controller110. After the first processor613/the second processor623outputs the digital signal to the controller110, the control logic thereof resets and clears the signal received by the analog-to-digital converter. For the embodiment ofFIG.4A/5A, the relationship between the signals output by the first processor613and the second processor623and whether a touch is sensed by the outer-side sensing circuit311/the inner-side sensing circuit312or not is shown in Table 1 below: TABLE 1Is a touchIs a touchsensed bysensed bythe firstthe secondSignal outputSignal outputcapacitivecapacitiveby the firstby the secondsensor 610?sensor 620?processor 613processor 623NoNo0000YesNo0100YesYes0110 The signal 00 output by the first processor613and the second processor623represents an invalid sensing signal, the signal 01 output by the first processor613represents the outer-side sensing signal, and the signal 10 output by the second processor623represents the inner-side sensing signal. As shown inFIG.6B, the touch sensing device105comprises the touch-slide type sensing circuit313, the touch-slide type sensing circuit313comprising a third capacitive sensor630, a third measurement circuit631and a third comparison circuit632connected in sequence, a fourth capacitive sensor640, a fourth measurement circuit641and a fourth comparison circuit642connected in sequence, and a third processor633connected to the third comparison circuit632and the fourth comparison circuit642. In some embodiments, the third capacitive sensor630/the fourth capacitive sensor640comprises two electrode plates separated by an insulating medium, and there is a certain distance between the two electrode plates. In response to a touch action of a hand, the distance between the two electrode plates of the third capacitive sensor630/the fourth capacitive sensor640changes, such that the capacitance of the third capacitive sensor630/the fourth capacitive sensor640changes. In some other embodiments, the third capacitive sensor630/the fourth capacitive sensor640comprises a touch electrode. Since human body tissues are filled with conductive electrolyte, a human body (e.g. a finger) will form a coupling capacitor with the third capacitive sensor630/the fourth capacitive sensor640when contacting or approaching the touch electrode, such that the capacitance value of the third capacitive sensor630/the fourth capacitive sensor640is increased. In some embodiments, the third measurement circuit631/the fourth measurement circuit641is configured for converting the capacitance of the third capacitive sensor630/the fourth capacitive sensor640and its change value into a corresponding voltage, current or frequency signal, thereby facilitating detection, calculation, etc. In some embodiments, the third measurement circuit631/the fourth measurement circuit641may comprise an operational amplifier type circuit, and the third capacitive sensor630/the fourth capacitive sensor640is connected to the operational amplifier type circuit. An output voltage of the operational amplifier type circuit is proportional to the capacitance of the third capacitive sensor630/the fourth capacitive sensor640. Therefore, the third measurement circuit631/the fourth measurement circuit641converts, by the change in a voltage value at the output end of the operational amplifier type circuit, a change in the capacitance value of the third capacitive sensor630/the fourth capacitive sensor640into a measured voltage signal for output. In the embodiment where the third capacitive sensor630/the fourth capacitive sensor640comprises two parallel electrode plates, the relationship between the output voltage of the operational amplifier type circuit and the distance between the electrode plates of the third capacitive sensor630/the fourth capacitive sensor640is linear. In some embodiments, the third comparison circuit632/the fourth comparison circuit642may be a voltage comparator. One input end of the voltage comparator receives the measured voltage signal output by the third measurement circuit631/the fourth measurement circuit641, and the other input end thereof receives a preset third threshold voltage signal/fourth threshold voltage signal; and an output end of the voltage comparator is connected to the third processor633. The third comparison circuit632/the fourth comparison circuit642respectively compares the measured voltage signal obtained from the third measurement circuit631/the fourth measurement circuit641with the preset third threshold voltage signal/fourth threshold voltage signal, and if the measured voltage signal exceeds the third threshold voltage signal/the fourth threshold voltage signal, a high level signal is output to the third processor633(or if the measured voltage signal exceeds the third threshold voltage signal/the fourth threshold voltage signal, a low level signal is output), and if the measured voltage signal does not exceed the threshold voltage signal, a low level signal is output to the third processor633(or if the measured voltage signal does not exceed the threshold voltage signal, a high level signal is output). By means of the preset threshold voltage signal, the third comparison circuit632/the fourth comparison circuit642can filter out the capacitance value change caused by other items accidentally triggering the sensing circuit, thereby making the touch sensing more precise. For example, when other items accidentally triggering the sensing circuit results in a small change of a capacitance value of the third capacitive sensor630/the fourth capacitive sensor640, the measured voltage signal does not exceed the threshold voltage signal, and thus a low level signal is output to the third processor633, i.e. no valid signal output is caused. The third processor633comprises the internally integrated control logic and analog-to-digital converter. The third processor633receives high level signals output by the third comparison circuit632and the fourth comparison circuit642, and, by means of the integrally integrated control logic and analog-to-digital converter in the third processor633, output different digital signals to the controller110according to different orders of receiving the high level signals output by the third comparison circuit632and the fourth comparison circuit642. For the embodiment ofFIG.4B/5B, the relationship between the signals output by the third processor633and whether a touch is sensed by the third capacitive sensor630/the fourth capacitive sensor640of the touch-slide type sensing circuit313or not is shown in Table 2 below: TABLE 2Is a touchIs a touchIs the third comparisonsensed bysensed bycircuit 632 or the fourththe thirdthe fourthcomparison circuit 642Signal outputcapacitivecapacitivethat first outputs a highby the thirdsensor 630?sensor 640?level?processor 633NoNo/00YesYesThe third comparison01circuit 632YesYesThe fourth comparison10circuit 642 The signal 00 output by the third processor633represents an invalid sensing signal, the signal 01 represents the first-direction touch-slide sensing signal, and the signal 10 represents a second-direction touch-slide sensing signal. FIG.7is a block diagram illustrating one embodiment of the handle driving device430in the embodiment ofFIGS.4A/5A and4B/5B. As shown inFIG.7, the handle driving device430comprises an electric motor710and a transmission mechanical structure720, wherein the electric motor710drives the transmission mechanical structure720. The electric motor710is connected to the controller110via the connection450, and the transmission mechanical structure720is connected to the handle body101to drive the handle body101. The transmission mechanical structure720can comprise components such as gears and racks. When the controller110outputs the first control signal/the first-direction control signal used for deploying the handle body101, the electric motor710rotates forward (or reversely) according to the control signal, and the forward rotation (or reverse rotation) of the electric motor710is converted into a linear motion in one direction by the transmission mechanical structure720, which drives the deploying of the handle body101. When the controller110outputs the second control signal/the second-direction control signal used for retracting the handle body101, the electric motor710rotates reversely (or forward) according to the control signal, and the reverse rotation (or forward rotation) of the electric motor710is converted into a linear motion in a direction opposite to the one direction by the transmission mechanical structure720, which drives the retracting of the handle body101. FIG.8Ais a flowchart illustrating one embodiment of a control flow800of the controller110in the embodiment shown inFIG.4A/5A.FIG.8Bis a flowchart illustrating one embodiment of a control flow850of the controller110in the embodiment shown inFIG.4B/5B. As shown inFIG.8A, for the embodiment shown inFIG.4A/5A of indicating and controlling the deploying and retracting of the handle body by using two sensing circuits, one embodiment of the control flow800of the controller110is specifically described in the following. In step801, the controller110determines whether a sensing signal generated by the outer-side sensing circuit311and/or a sensing signal generated by the inner-side sensing circuit312is received, and if yes, the controller110turns the operation to step802, otherwise step801continues to be executed. In step802, the controller110determines whether one side sensing signal is received or two side sensing signals are received. If one side sensing signal is received, the controller110turns the operation to step803, and if two side sensing signals are received, the controller110turns the operation to step807. In step803, the controller110determines whether the handle is at the retracted position, and if the handle is at the retracted position, the controller110turns the operation to step804, otherwise the controller110returns the operation to step801. In step804, the controller110waits for the one side sensing signal to cease, and turns the operation to step805after determining that the one side sensing signal has ceased. In step805, the controller110sends a handle deploying signal to the handle driving device430, and then turns the operation to step806. In step806, the handle driving device430drives the deploying of the handle, and then the controller110returns the operation to step801. In step802, if the controller110determines that two side sensing signals are received, the controller turns the operation to step807. In step807, the controller110determines whether the handle is at the deployed position, and if the handle is at the deployed position, the controller110turns the operation to step808, otherwise the controller110returns the operation to step801. In step808, the controller110waits for the two side sensing signals to cease, and turns the operation to step809after determining that the two side sensing signals have ceased. In step809, the controller110sends a handle retracting signal to the handle driving device430, and then turns the operation to step810. In step810, the handle driving device430drives the retracting of the handle, and then the controller110returns the operation to step801. As shown inFIG.8B, for the embodiment shown inFIG.4B/5B of indicating and controlling the deploying and retracting of the handle body by using one sensing circuit, one embodiment of the control flow850of the controller110is specifically described in the following. In step851, the controller110determines whether a sensing signal generated by the touch-slide type sensing circuit313is received, and if so, the controller110turns the operation to step852, otherwise step851continues to be executed. In step852, the controller110determines whether the received sensing signal is a first-direction touch-slide sensing signal or a second-direction touch-slide sensing signal, and if it is the first-direction touch-slide sensing signal, the controller110turns the operation to step853, and if it is the second-direction touch-slide sensing signal, the controller110turns the operation to step857. In step853, the controller110determines whether the handle is at the retracted position, and if the handle is at the retracted position, the controller110turns the operation to step854, otherwise the controller returns the operation to step851. In step854, the controller110waits for the first-direction touch-slide sensing signal to cease, and turns the operation to step855after determining that the first-direction touch-slide sensing signal has ceased. In step855, the controller110sends a handle deploying signal to the handle driving device430, and then turns the operation to step856. In step856, the handle driving device430drives the deploying of the handle, and then the controller110returns the operation to step851. In step852, if the controller110determines that the received signal is the second-direction touch-slide sensing signal, then the controller turns the operation to step857. In step857, the controller110determines whether the handle is at the deployed position, and if the handle is at the deployed position, the controller110turns the operation to step858, otherwise the controller110returns the operation to step851. In step858, the controller110waits for the second-direction touch-slide sensing signal to cease, and turns the operation to step859after determining that the second-direction touch-slide sensing signal has ceased. In step859, the controller110sends a handle retracting signal to the handle driving device430, and then turns the operation to step860. In step860, the handle driving device430drives the retracting of the handle, and then the controller110returns the operation to step851. FIG.9Ais a block diagram illustrating functional modules according to one embodiment of the controller110in the embodiment ofFIG.4A/4B.FIG.9Bis a block diagram illustrating functional modules according to one embodiment of the controller110in the embodiment ofFIG.4B/5B. As shown inFIG.9A, for the embodiment shown inFIG.4A/5A of indicating and controlling the deploying and retracting of the handle body by using two sensing circuits, the controller110can comprise a processor904, a memory912, an input interface906, an output interface908and a bus902, and realize data transmission among the processor904, the memory912, the input interface906and the output interface908via the bus902. The input interface906receives sensing signals (the outer-side sensing signal and the inner-side sensing signal) from the touch sensing device105via the connections441and442, and then the processor904generates corresponding control instructions (including a control instruction for deploying a handle or retracting a handle, and a control instruction for locking a vehicle door lock, etc.) based on programs or instructions914(including a program or instruction that implements the control flow800as shown inFIG.8A) pre-stored in the memory912. The output interface908sends, to the handle driving device430, a control instruction via the connection450that is generated by the processor904for deploying the handle or retracting the handle, thereby controlling the handle driving device430so that the same drives the deploying or retracting of the handle body101. The output interface908also sends the corresponding control instruction to other operational components (e.g. a vehicle door) of the vehicle, so as to perform other operations on the vehicle (e.g. locking the vehicle door). As shown inFIG.9B, for the embodiment shown inFIG.4B/5B of indicating and controlling the deploying and retracting of the handle body by using one sensing circuit, the controller110can comprise a processor904, a memory912, an input interface906, an output interface908and a bus902, and realize data transmission among the processor904, the memory912, the input interface906and the output interface908via the bus902. The input interface906of the controller110receives sensing signals (the first-direction touch-slide sensing signal and the second-direction touch-slide sensing signal) from the touch sensing device105via the connection443, and then the processor904generates corresponding control instructions (including a control instruction for deploying a handle or retracting a handle, and a control instruction for locking a vehicle door lock, etc.) based on programs or instructions914(including a program that implements the control flow850as shown inFIG.8B) pre-stored in the memory912. The output interface908sends, to the handle driving device430, a control instruction via the connection450that is generated for deploying the handle or retracting the handle, thereby controlling the handle driving device430so that the same drives the deploying or retracting of the handle body101. The output interface908also sends the corresponding control instruction to other operational components (e.g. a vehicle door) of the vehicle, so as to perform other operations on the vehicle (e.g. locking the vehicle door). It needs to be noted that the handle body of the present disclosure is not limited to be of the specific structure and to be at the specific deployed position, retracted position and release position in the embodiments shown inFIGS.1A-3B, and the handle control system and its corresponding control method according to the present disclosure can be used as long as the handle body can be moved away from a hidden position (that is, the position where the handle body is flush with the vehicle door) and return to the hidden position. For example, the deployed position of the handle body of the present disclosure may be a position where the handle body is rotated outward around a shaft from a hidden position by a certain angle, the release position thereof may be a position where the handle body continues to rotate outward from the deployed position by a certain angle, and the retracted position thereof is the hidden position of the handle body. The handle body in such an embodiment is similar to the handle body in the Chinese patent application no. 201711423248.9, entitled “Hidden type handle assembly”, and filed by the applicant on Dec. 25, 2017. The handle system and the control method provided in the present disclosure facilitate the user in controlling a vehicle by means of touch sensing. For example, by lightly touching a certain region by hand or drawing a certain pattern, the vehicle can be controlled and operated accordingly. The handle system and the operation method thereof according to the present disclosure require smaller operation strength, and are more flexible and convenient, and also more durable than the conventional button control manner. Moreover, compared to the long-distance sensing-controlled handle, the handle system and the operation method thereof according to the present disclosure are less prone to errors, and can ensure the touch feel desired by a user. This description uses examples to disclose the present disclosure, in which one or more examples are illustrated in the drawings. Each example is provided to explain the present disclosure but is not intended to limit the present disclosure. In fact, it would have been obvious to those skilled in the art that various modifications and variations can be made to the present disclosure without departing from the scope or spirit of the present disclosure. For example, the illustrated or described features as part of one embodiment can be used with another embodiment to provide a further embodiment. Thus, it is intended that the present disclosure cover the modifications and variations made within the scope of the appended claims and their equivalents. | 49,501 |
11859420 | DETAILED DESCRIPTION According toFIGS.1to3, the sterile supply-container seal1according to a preferred embodiment of the present invention has a locking bolt or bar3, at one end portion of which, preferably end/front side, a clip or fold tab5is arranged/formed, preferably in one piece of material, which in the construction position (unactuated state) according toFIG.3preferably extends essentially at right angles to the longitudinal axis S of the locking bolt3. At one end portion, the fold tab5forms a push/actuation surface or button7approximately in the area of the locking bolt3, the tab side of which faces away from the locking bolt3, and at its other end portion it forms a (manually) bendable or foldable connection strap9, at the free end/end portion of which a bolt or pin13is arranged, preferably in one piece of material, which preferably extends essentially at right angles to the fold tab/connection strap on its tab side facing the locking bolt3. In the present case, the fold tab5has a predetermined bending line/predetermined bending bar11which divides/separates the push/actuation button7from the connection strap9. It should be expressly noted at this point that the predetermined bending line11is purely optional and instead only the flexibility of the connection strap9can be used to bend it. Finally, the side of the fold tab5facing away from the locking bolt3can serve as a carrier surface for an indicator device (not shown further) which can indicate the sterilization state of the container (for example by discoloration as a result of a heating process). At the free end/end portion of the bolt13, a latch device15is preferably arranged as a single piece of material, according toFIG.2preferably in the form of an anchor with two flexible/elastic wings15a,15bset in the manner of arrows and optionally of a stop surface15c, which is formed on the free front side of the bolt/latch device. Finally, the bolt13has a longitudinal groove13a, which is formed on the free connection-strap front side between connection groove9and latch device15, the latch device15forming a centering surface/centering device15daxially between the two wings15a,15b, which is aligned in axial extension to the longitudinal groove13a. The locking bolt3forms at its free end portion a preferably beak-shaped insertion inclination3a, and in a central portion it forms a push-in/latch compartment17open in the direction of the bolt13. This push-in/latch compartment17has approximately an inner dimension corresponding to the outer dimension of the bolt13, in particular of the latch device15, in such a way that the latter can be inserted into the push-in/latch compartment17. In addition, indentations17a,17bare formed on two opposing side walls of the push-in/latch compartment17into which the wings15a,15bof the anchor-shaped latch device15latch (or engage) when it is inserted into the push-in/latch compartment17. In order to limit this insertion movement, the push-in/latch compartment17optionally forms a compartment bottom17cagainst which the stop surface15cof the latch device15can abut. Finally, a plate-shaped or wedge-shaped projection17dis formed/arranged on the push-in/latch compartment17, which projects into the push-in/latch compartment17and optionally forms a kind of blade/cutting edge at its free front edge. The projection17dis arranged in such a way that it comes into sliding engagement with the centering surface15don the latch device15of the bolt13when the latter is inserted into the push-in/latch compartment17. Optionally, a material application (thickening) or a strip-shaped projection3bcan be formed on the locking bolt3in the area of the clip/fold tab5, which is provided to compensate for dimensional tolerances and, if applicable, to brace/clamp the locking bolt3in the passage opening of an element to be sealed of the container. FIGS.4and5illustrate the principle of operation of the container seal according to the invention. Accordingly, the seal1is provided and designed for the locking bolt3to be inserted as a rigid/non-destructible sealing component into the overlapping passage openings of two elements of a sterile supply container, for example, which are movable relative to each other, in order to lock them against relative movement. Such elements can be, for example, a container lid and a container tray or two levers of an opening/closing mechanism of the container or similar elements. At this point, it should be noted that these elements are not part of the subject matter itself, but merely describe a possible application of the seal1according to the invention for a better technical understanding of its operation. As soon as the locking bolt3is inserted into the passage openings mentioned (not shown) in such a way that the fold tab5is on one side and the push-in/latch compartment17is on the other side of the elements to be locked, the connection strap9is bent/folded and the bolt13, in particular the latch device15at the free end of the bolt13, is pushed into the push-in/latch compartment17until the two wings15a,15bof the latch device15latch (or engage) in the indentations17a,17bon the push-in/latch compartment17and thus lock the seal1. This push-in movement is assisted by the wedge-shaped projection17d, which slides along in/on the centering device15dand finally engages in the longitudinal groove13aon the bolt. The insertion path is finally limited by the compartment bottom17a, on which the stop surface15dof the latch device15abuts. In order to break the seal according to the invention and to be able to move the two sealed container elements relatively again, essentially two operations are required according to the invention: First, the bolt13has to be pulled/torn out of the push-in/latch compartment17by tearing the latch device15off the bolt13. This tear-off process can, for example, be (additionally) supported by the wedge-shaped projection17d, which, as already indicated above, optionally forms a cutting edge on its free front edge, which (if technically implemented) rests against a transition area forming a predetermined breaking point14between bolt13and anchor-shaped latch(-in) device15and shears off the latch device15when the bolt13is pulled out. If no corresponding cutting edge is formed, the predetermined breaking point14between bolt13and latching device15is torn apart solely by the manual actuation/pulling force on the bolt13. Since the wings15a,15bof the latch device15remain latched/engaged/(inter)locked in the two indentations17a,17bof the push-in/latch compartment17, the (fragmented) latch device remains inside the push-in/latch compartment17in the additional function of a catch cage. This condition is shown inFIG.5. Only now can the locking bolt preventing the relative movement of the two sealed container elements be pulled manually from the passage openings of the container elements concerned, which are not shown further, in order to release their relative movement. | 6,996 |
11859421 | DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS In this detailed description, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments which may be practiced. Reference now should be made to the drawings, in which the same reference numbers are used throughout the different figures to designate the same components. These embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments and disclosure. It is to be understood that other embodiments may be utilized, and that logical, mechanical, electrical, and other changes may be made without departing from the scope of the embodiments and disclosure. In view of the foregoing, the following detailed description is not to be taken as limiting the scope of the embodiments or disclosure. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms “a”, “an”, and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising” or “includes” and/or “including” when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and/or groups thereof. It will be appreciated that for simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the implementations described herein. However, it will be understood by those of ordinary skill in the art that the implementations described herein may be practiced without these specific details. In other instances, well-known methods, procedures and components have not been described in detail so as not to obscure the implementations described herein. Also, the description is not to be considered as limiting the scope of the implementations described herein. The detailed description set forth herein in connection with the appended drawings is intended as a description of exemplary embodiments in which the presently disclosed apparatus and system can be practiced. The term “exemplary” used throughout this description means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other embodiments. Illustrated inFIG.1is a partial perspective view showing a door locking device100in locked position, in use with an out-swing door105in an exemplary embodiment. Door locking device100is adapted for securing the out-swing door105against forced entry. To aid in ready understanding of the scope and utility of the disclosed subject matter, the out-swing door105will be further described. The reference “Parts of a Door Explained” by Diffey, N. (Salisbury Joinery blog dated Nov. 7, 2017) viewed Nov. 2, 2021 at https://www.salisburyjoinery.com/blog/parts-of-a-door-explained, is incorporated by reference in entirety. Out-swing door105(FIG.1) may include a stile mounted to a set of door hinges supported by a door frame110(FIG.1) for pivotal movement about a door hinge vertical axis, between a closed position abutting the door frame110and an open position pivoted away from the closed position. The closed position is shown inFIG.1. The set of door hinges is mounted to the door frame110and door105, for out-swing movement. Door105includes a stile extending parallel to the door hinge vertical axis from a bottom rail to a top rail thereof. The door105has a lock stile112(FIG.1) opposite the stile. The door105has a door body115(FIG.1) including a planar door interior surface120(FIG.1) facing the door frame110. Door105has a door exterior surface122(shown inFIG.4) facing opposite the interior surface120(shown inFIG.1). The door body115has a continuous door peripheral edge125extending from the interior surface120to the exterior surface in intersecting perpendicular relation thereto. The door peripheral edge125includes a door inside edge defined along the stile proximate the door hinge vertical axis. Door peripheral edge125includes a door outside edge130extending vertically and defined along the lock stile112in opposed parallel relation to the door inside edge. Door105includes a door handle140at the lock stile112, which is operable for manual operation. The door frame110includes an elongated first jamb extending in the vertical direction in corresponding relationship to the door inside edge, and in the closed position abutting the inside edge. Door frame110includes an elongated second jamb135extending in the vertical direction in corresponding relationship to the door outside edge130, and in the closed position abutting the outside edge. Referring toFIG.1, door105may be configured for use with door locking device100of this disclosure. Door body115may include a first device mounting aperture140(shown in FIG.24) defined in the door body115. The first device mounting aperture140may extend through the door body115to connect the door interior surface120with the door exterior surface. The first device mounting aperture140may be spaced apart from the door outside edge130at a first offset distance in the horizontal direction. As shown inFIG.1, door locking device110may include a mounting plate160configured to be secured to the door interior surface120. Door locking device100may include a fastener165suitable to secure mounting plate160to door body115against door interior surface120. Although other suitable fasteners165may be used, in the illustrated embodiment, fastener165may be a suitable first threaded fastener combination170. In an exemplary embodiment as shown inFIG.1, first threaded fastener combination170may include an elevator bolt174which may have a bolt stem having male threads configured for mating threaded engagement with a nut173(FIG.3) having female threads. Door locking device100may include a plurality of first minor fasteners172suitable to be received in a corresponding plurality of minor apertures196(FIG.2) cooperating to secure mounting plate160to door body115against door interior surface120. As shown inFIG.1, mounting plate160may include a first major body180having a planar first rear surface185configured to abut the door interior surface120. First major body180may have a planar first front surface190disposed in opposed parallel relationship to the first rear surface185. Mounting plate160may include a first mounting aperture195extending through the first major body180from the first rear surface185to first front surface190in perpendicular relationship with the same first front and rear surfaces185,190. First mounting aperture195may be positioned in common axial alignment with the first device mounting aperture140(FIG.24) of the door105to receive the first threaded fastener combination170extending therethrough. The first threaded fastener combination170in the aligned apertures195,140may extend through door body115and the first major body180to secure the mounting plate160against door body115with the first rear surface185abutting door interior surface120. As shown inFIG.1, mounting plate160may have a first outside edge200(shown inFIG.3) may have a vertical axis201(shown inFIG.3) proximate the door outside edge130(shown inFIG.1). Mounting plate160may have a set of first receiver ears210proximate first outside edge200. The set of first receiver ears210may be spaced apart along an elongated hinge pin assembly270may have a hinge pin vertical axis275. The hinge pin vertical axis275is spaced from door outside edge130and first outside edge200of mounting plate160. More particularly, it will be understood that first outside edge200of mounting plate160is proximate continuous door outside interior edge132or corner located at intersection of door outside edge130with door interior surface120. Door outside interior edge132extending along a respective vertical axis is continuous. As shown inFIG.1, mounting plate160may include a set of first receiver bays290spaced apart along hinge pin vertical axis275adjacent the set of first receiver ears210in alternating relationship with the first receiver ears210. Each of the first receiver bays290may be defined adjacent a corresponding first receiver ear210. In the alternative, the first receiver bays290may be defined between two adjacent first receiver ears210, which may include an upper adjacent and lower adjacent of the first receiver ears210located on opposite upper and lower sides of first receiver bay290therebetween. The set of first receiver bays290may be configured to receive in mating relationship a corresponding set of second receiver ears610of an adjacent clasp swing plate560. The set of second receiver ears610may dock in the set of first receiver bays290in registration relationship therewith. As shown inFIG.1, first receiver ears210may extend from first major body180of mounting plate160in integral fixed relationship therewith. Each of the first receiver ears210may include a proximal portion215adjoining first major body180of mounting plate160proximate first outside edge200and first front surface190thereof. Each of the first receiver ears210may include a distal portion220spaced from the proximal portion215thereof and generally spaced in a lateral direction from first outside edge200. Each of first receiver ears210may include first receiver wall222extending to the distal portion220from proximal portion215and returning from distal portion220to proximal portion215. The first receiver wall222defines a first receiver aperture235intermediate the distal portion220and proximal portion215. The first receiver wall222may have a continuous tubular first receiver inner surface239spaced from a first receiver aperture vertical axis250in equidistant relationship therefrom, defining a first receiver aperture235having a first receiver wall inner radius. The first receiver wall222may include continuous first receiver wall outer surface237disposed in spaced opposed relationship to the first receiver wall inner surface239. The first receiver wall222in the vertical direction may extend from a continuous first receiver top surface240to a continuous first receiver bottom surface241disposed in spaced opposing relationship. The first receiver wall222may terminate at the continuous first receiver top surface240. The first receiver top surface240may extend from the first receiver wall outer surface237to first receiver wall inner surface239in perpendicular intersecting relationship therewith. The first receiver top surface240may intersect the first receiver wall outer surface237at a continuous first top surface outer edge242spaced from the first receiver aperture vertical axis250in equidistant relationship at a first receiver wall outer radius. The first receiver wall top surface250may intersect the first receiver wall inner surface239at a continuous first top surface inner edge243spaced from the first receiver aperture vertical axis250in equidistant relationship at the first receiver wall inner radius. As shown inFIG.1, the first receiver wall top surface240in a direction perpendicular to the first receiver aperture vertical axis250may have a first receiver top surface primary width between the first top surface inner edge243and the first top surface outer edge242, which is a difference between the outer radius and inner radius of first receiver wall222; As shown inFIG.1, the first receiver wall bottom surface241may be disposed in spaced opposed relationship to the first receiver wall top surface240. The first receiver wall222may have a substantially uniform width from the first receiver wall top surface240to the first receiver wall bottom surface241. The first receiver wall bottom surface241may have a first receiver wall bottom surface primary width between a first bottom surface inner edge244and first bottom surface outer edge247which is the difference between the first receiver wall outer radius and the first receiver wall inner radius. As shown inFIGS.1,2and3the first receiver wall top surface240may include a major rest248proximate the first front surface190of the first major body180of mounting plate160. The major rest248may have a major rest height that defines maximum height of the first receiver wall222to support the clasp swing plate560at uppermost position thereof in relation to mounting plate160. The major rest248at a second receiver wall bottom surface641of clasp swing plate560may provide supporting engagement with second receiver ears610at uppermost position of same, and thus may support clasp swing plate560at uppermost position thereof, when clasp swing plate560is pivoted to unlocked position and aligned in abutting relationship at substantially zero degrees (0°) in relation to said mounting plate160. As shown inFIGS.1,2and3the first receiver wall top surface240may include an elongated vertical first locking channel251defined in first receiver wall222proximate hinge pin vertical axis275at substantially ninety degrees (90°) in relation to mounting plate160. The first locking channel251may interrupt the first receiver wall222, to form an empty, open gap in the first receiver wall222. The first locking channel251may be sized to receive therein a first proximal portion615or neck of corresponding second receiver wall622of second receiver ear610in lowermost position (shown inFIG.1) thereof, when clasp swing plate560in corresponding lowermost position is rotated about hinge pin vertical axis275to locked position in perpendicular relationship at substantially ninety degrees (90°) in relation to mounting plate160. The first locking channel251at first locking channel bottom wall252defining minimum height thereof may provide supporting engagement with second receiver wall bottom surface641of second receiver ear610at lowermost position (shown inFIG.1) of same, and thus may support clasp swing plate560at lowermost position (shown inFIG.1) in relation to mounting plate160, when clasp swing plate560is pivoted to locked position (shown inFIG.1) and aligned in securing relationship with door frame anchor bolt320, in perpendicular relationship at substantially ninety degrees (90°) in relation to mounting plate160. As shown inFIG.10, the first receiver wall top surface240may include an elongated declined slide surface340extending from first transition343at first major rest248at maximum height of first receiver wall top surface240downward to second transition346at second transition height of first receiver wall top surface240, where the second transition height is determined to enable corresponding second receiver ear610, by force of gravity on second receiver ear610, to pass downward from the upper end of declined slide surface340at first transition343and across declined slide surface340to clear second transition346, and then to drop in first locking channel251to rest on first locking channel bottom wall252thereof when clasp swing plate560pivots through a range of travel which is about ninety degrees (90°) about hinge pin vertical axis275, from unlocked position in the uppermost position in abutment at substantially zero degrees (0°) in relation to mounting plate160, to locked position in the lowermost position perpendicular at substantially ninety degrees (90°) in relation to mounting plate160. The first declining slide surface340at the first lower second transition346may introduce the second proximal portion615or neck of the second receiver ear610into the vertical first locking channel251. Referring toFIG.3, the first locking channel251may interrupt the first receiver wall222, to form an empty, open gap in the first receiver wall222. The first locking channel251may be sized to receive therein a first proximal portion615or neck of corresponding second receiver wall622of second receiver ear610in lowermost position thereof, when clasp swing plate560in corresponding lowermost position is rotated about hinge pin vertical axis250to locked position in perpendicular relationship at substantially ninety degrees (90°) in relation to mounting plate160. The first locking channel251by cooperation of first locking channel major wall253, opposed first locking channel upper minor wall255and lower minor wall254, and locking channel bottom wall252, engage the second receiver ear610to secure the clasp swing plate560in locked position, substantially perpendicular to mounting plate160, in lowermost position in relation to mounting plate160. Force of gravity biases the second receiver ear610and clasp swing plate560to move into, and to be retained, the lowermost position when clasp swing plate560is pivoted to locked position and aligned in perpendicular relationship at substantially ninety degrees (90°) in relation to the mounting plate160. As shown inFIG.1, door locking device100may include a door frame anchor assembly315configured to be mounted to the second jamb135of door frame110. The door frame anchor assembly315may include a door frame anchor mounting plate320configured to be secured to the second jamb135to support a door frame anchor bolt330. Door frame anchor mounting plate320may include a spaced plurality of minor mounting apertures325configured to receive corresponding threaded screws335to fix the door frame mounting plate320against the second jamb135. Door frame anchor mounting plate320may include a primary aperture340having female threads and configured for mating threaded engagement with a door frame anchor bolt330having male threads333for such mating threaded engagement. The door frame anchor bolt330includes an enlarged anchor bolt head334and adjoined bolt stem332having male threads. The door frame anchor assembly315includes an anchor bolt setting nut333for setting length of door frame anchor bolt330in relation to major anchor aperture323having female threads defined in door frame anchor plate320for receiving the door frame anchor bolt330in mating threaded engagement therewith. Referring toFIG.1, enlarged anchor bolt head345has a cross-sectional size greater than adjoining anchor bolt stem346cross-sectional size. The anchor bolt head345is located at a clasp cut-out height determined for the anchor bolt head345to be received in a clasp cutout561of the clasp swing plate560. The anchor bolt head345is located at a clasp cut-out horizontal offset distance, in relation to the hinge pin vertical axis250, determined for the anchor bolt head345to be received in the clasp cutout561of the clasp swing plate560. Referring toFIG.1, the clasp swing plate560is configured for releasable secured engagement with the door frame anchor assembly315. Referring toFIG.1, the clasp swing plate560includes second major body580including second front surface590disposed in opposition to second rear surface585. Clasp swing plate560may include a plurality of second receiving ears610similar to first receiving ears210, except having a respective second receiver wall top surface240that is flat and has uniform height. Clasp swing plate560may include a plurality of second receiving bays690similar to first receiving bays290, except having a respective second receiver bay top surface and bottom surface that are flat and have uniform height. Clasp cut-out561extends through second major body580between second front surface590and second rear surface585to define clasp cut-out aperture563having lower major region564in open communication with upper minor region566. The clasp swing plate560is configured for vertical translation movement in relation to the door frame anchor bolt320. The clasp swing plate560may move between an unlocked, uppermost position (shown inFIGS.5,6,8,9,11,22,29,30,33and36) pivoted substantially parallel at substantially zero degrees (0°) in relation to the mounting plate160where a first major rest248of a first receiver ear210supports the clasp swing plate560in the uppermost position relative to a hinge pin vertical axis250and mounting plate160; and a locked, lowermost position (shown inFIGS.1,7,10,16,17,27,28,35and38) pivoted substantially perpendicular at substantially ninety degrees (90°) in relation to the mounting plate160where a first locking channel bottom wall252supports the clasp swing plate560in the lowermost position relative to the hinge pin vertical axis250and mounting plate160. The clasp swing plate560, when pivoted about the hinge pin vertical axis250to substantially perpendicular at substantially ninety degrees (90°) in relation to the mounting plate160, which positions the clasp swing plate560substantially perpendicular to the door frame anchor bolt330to be secured in anchoring engagement with the door frame anchor bolt330, is biased by force of gravity to move to the lowermost position to receive only the anchor bolt stem332in an upper minor region566of an anchor bolt aperture563defined by a clasp cut-out561, and to be positively retained in the lowermost position by force of gravity until manually raised by a user to the uppermost position. The clasp swing plate560, remaining in the same position pivoted at substantially ninety degrees (90°) in relation to the mounting plate160and thus positioned substantially perpendicular to the door frame anchor bolt330to be secured in anchoring engagement with the door frame anchor bolt330, may be connected to the door frame anchor bolt330, or removed from connection to the same, by a user manually raising the clasp swing plate560from the lowermost position to the uppermost position that aligns a lower major region566of the anchor bolt aperture563defined by the clasp cut-out561with the door frame anchor bolt330to enable the clasp cut-out561to clearing and receive, or clear and be removed from, the enlarged anchor bolt head334. The clasp cut-out561defines a clasp anchor bolt aperture563having a lower major region564adjoining an upper minor region566in open communication. The lower major region564is configured to clear and receive the enlarged anchor bolt head334of door frame anchor bolt330when the clasp swing plate560occupies the uppermost position relative to the door frame anchor assembly315. The upper minor region566is configured to receive only the anchor bolt stem332of door frame anchor bolt330, without clearing the enlarged anchor bolt head334, when the clasp swing plate560occupies the lowermost position relative to the door frame anchor assembly315and mounting plate160. The clasp cut-out561is located at the clasp cut-out horizontal offset distance determined for the clasp cut-out561at the uppermost position to clear and receive the enlarged anchor bolt head334, and for the clasp cut-out561at the lowermost position to receive the anchor bolt stem332without clearing the enlarged anchor bolt head334. The clasp swing plate560is biased by force of gravity for vertical translation movement to the lowermost position from the uppermost position when extending toward the anchor bolt at substantially ninety degrees (90°) in relation to the mounting plate160. The clasp swing plate560is retained in the lowermost position by the gravity biasing force to lock the clasp swing plate560in locking, anchored relationship with the door frame anchor bolt330. The clasp anchor bolt aperture563defined by clasp cut-out561at the upper minor region may receive only the anchor bolt stem332in registration relationship when captured behind the enlarged anchor bolt head334. The clasp swing plate560may be disconnected and removed from the position captured behind the enlarged anchor bolt head334only when manually raised by a user exceeding the positive biasing force of gravity that positively retains the clasp swing plate in the lowermost position, captured behind the enlarged anchor bolt head334. Apparatus, methods and systems according to embodiments of the disclosure are described. Although specific embodiments are illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement which is calculated to achieve the same purposes can be substituted for the specific embodiments shown. This application is intended to cover any adaptations or variations of the embodiments and disclosure. For example, although described in terminology and terms common to the field of art, exemplary embodiments, systems, methods and apparatus described herein, one of ordinary skill in the art will appreciate that implementations can be made for other fields of art, systems, apparatus or methods that provide the required functions. The invention should therefore not be limited by the above-described embodiments, methods, and examples, but by all embodiments and methods within the scope and spirit of the invention. In particular, one of ordinary skill in the art will readily appreciate that the names of the methods and apparatus are not intended to limit embodiments or the disclosure. Furthermore, additional methods, steps, and apparatus can be added to the components, functions can be rearranged among the components, and new components to correspond to future enhancements and physical devices used in embodiments can be introduced without departing from the scope of embodiments and the disclosure. One of skill in the art will readily recognize that embodiments are applicable to future systems, future apparatus, future methods, and different materials. All methods described herein can be performed in a suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”), is intended merely to better illustrate the disclosure and does not pose a limitation on the scope of the disclosure unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the disclosure as used herein. Terminology used in the present disclosure is intended to include all environments and alternate technologies that provide the same functionality described herein. | 26,353 |
11859422 | DETAILED DESCRIPTION OF THE INVENTION Overview Enclosure assemblies are universally used to secure and protect its contents such as delicate electronics of a control box. Accessibility to the enclosure assembly, such as to make repairs or perform diagnostics, is an essential function of the enclosure assembly, but often times the location of these enclosure assemblies are in difficult-to-reach locations that are often cramped or constrained by other structures. Thus, often, even if the enclosure assembly can be reached, the cover may not be able to be easily removed in the way it was designed because of unforeseen structures being in the way or not enough clearance space to open the cover in the manner designed. Thus, the function of accessibility is essential, and typically accomplished using a lid or cover in conjunction with the enclosure housing. Such lids or covers are attached to the enclosure housing by either relatively permanent or temporary means. Relatively permanent systems of attaching a cover to its enclosure housing may include screws, nuts and bolts, welding and the like. A relatively permanent attachment renders the enclosure's opening practically inaccessible in the field as the cover cannot be quickly removed and/or removed without the use of tools. Furthermore, even if removed, it is less likely that, after access, the cover will be reattached, leaving the contents exposed thereafter. On the other hand, temporary attachment systems are typically snap-type fittings or hinges. Snap-type fittings secure the lid over the opening of the enclosure housing and allow for the cover's removal therefrom by unsnapping the cover from the enclosure housing to provide access to the space within the enclosure. Hinges allow the cover to swing away from the enclosure housing to which it is attached, thereby providing access to the space within the enclosure. A problem exists with current attachment systems as they are based on different design concepts that require differing manufacturing techniques, and a multitude of different designs increases manufacturing and inventory costs. Moreover, the currently known attachment systems fail to provide the flexibility when accessing the space within the enclosure to either remove the cover in its entirety or just swing the cover away from the enclosure housing. For example, hinge attachment systems can be problematic in the event there is not enough room for the cover to pivot open (e.g., cramped spaces at the control box or other enclosure setting). Snap-type systems are generally less secure and/or protective and the cover may not be reattached after removal. Accordingly, there is a need for an enclosure assembly that offers the flexibility of a cover that can swing open with an attachment system and/or slide open either partially or be removed completely from the enclosure housing for access to the space within the enclosure. A single attachment system solving these challenges can meet the needs of all the aforementioned various applications and minimizes costs of manufacturing, inventory, and the like. Referring more specifically to the drawings, for illustrative purposes the present invention is generally shown in a first embodiment of the leafless joint apparatus with respect toFIG.1throughFIG.7. A second embodiment of the leafless joint apparatus is generally shown with respect toFIG.8throughFIG.11. It will be appreciated that the apparatus may vary as to configuration and as to details of the parts without departing from the basic concepts as disclosed herein. Referring first toFIG.1throughFIG.3, an enclosure assembly10embodying the present invention is generally shown. Enclosure assembly10generally comprises an enclosure housing12, an enclosure cover14and an attachment system16for attaching enclosure cover14to the enclosure housing12. Enclosure cover14is shown in a partly swung open position from the enclosure housing12thereby providing access to a space18within enclosure housing12. Referring now toFIG.2, a side view of the enclosure assembly10of the present invention is generally shown. As can be seen in the figure, enclosure cover14is shown on a completely closed position relative to enclosure housing12thereby sealing space18within enclosure housing12. The sealing of space18of the enclosure housing12may provide an airtight, watertight, or hermetic seal to isolate the space18from the environment as necessary, depending on the application. The composition of materials used in the fabrication of enclosure assembly10may be metal, plastic, wood, or any suitable material structurally suitable for its intended purpose. InFIG.3, enclosure assembly is shown with enclosure cover14in a mostly swung open position relative to enclosure housing12thereby providing full access to space18within enclosure12. As seen inFIG.1, enclosure cover14may include rolled tabs15aand15bthat clear notches17aand17bdisposed on a lip that extends from enclosure housing12thereby allowing enclosure cover14to swing away from enclosure housing12. It can be seen that when enclosure cover14is on the closed position, sliding enclosure cover14in either longitudinal direction will cause rolled tabs15aand15bto engage the lip, thereby preventing enclosure cover14from swinging open. Referring now toFIGS.4A and4B, enclosure assembly10is shown, wherein enclosure cover14is depicted in a partially slid open position relative to enclosure housing12. In this position shown, partial access to space18within enclosure housing12is provided. The arrow shown in the figure is a longitudinal direction that exemplifies how enclosure cover14may be slidably moved longitudinally relative to enclosure housing12to provide partial access to space18. It is contemplated the cover12may also be slidably moved in a longitudinal direction to the opposite of that shown by the arrow to also provide partial access to space18. When enclosure cover14is slidably moved beyond the edge of enclosure housing12in either direction, enclosure cover14may be completely detached from enclosure housing12thereby providing full access to space18within enclosure12. Cylindrical receiving member26(described below) may also incorporate a flange21disposed at one end to limit the longitudinal movement of enclosure cover14and/or to maintain enclosure cover14in a fixed position relative to enclosure housing12. It is contemplated that knockout hole(s)19may be incorporated in enclosure housing12or enclosure cover14that will offer access of the internal components to external elements, such as electrical wiring, plumbing, computer displays, etc. Bent tabs23may also be incorporated on enclosure cover14and disposed at approximately each longitudinal end thereof. Bent tabs23may be bent upward away from space18as shown in23cand23dor downward into space18as shown in23aand23bof enclosure housing12. For example, when bent tab23ais bent upward, it may serve as a grab handle for enclosure cover14, and when bent tab23bis bent downward, it locks enclosure cover14in place and prevents its sliding relative to enclosure housing12. Referring toFIG.5, an enlarged view of attachment system16of enclosure assembly10is generally depicted. At least one edge20of enclosure housing12comprises a lip22. The distal end24of lip22extends to and forms a cylindrical receiving member26. At least one side28of enclosure cover14extends to and forms a cylindrical engaging member30. Cylindrical engaging member30surrounds and slidably engages cylindrical receiving member26concentrically, while allowing enclosure cover14to pivot around a central axis of cylindrical receiving member26, thereby causing enclosure cover14to swing open or close relative to enclosure housing12. Thus, in the context of hinge devices, cylindrical engaging member30serves the function of a hinge knuckle, whereas cylindrical receiving member26serves the function of a hinge pintel or pin. In this case, the “knuckle” is coupled to, or integrated with, enclosure cover14, whereas the “pintel” is coupled to, or integrated with, enclosure housing12. It is appreciated that other embodiments can exist in which this implementation is reversed such as the “knuckle”being integrated with enclosure housing12and the “pintel” being integrated with enclosure cover14. Regardless, because the “pintel” and “knuckle” are designed to be integrated with distinct elements, one being enclosure housing12and the other being enclosure cover14, there is no need for separate “leaf” elements as in conventional hinges. Rather, the “pintel” (e.g., cylindrical receiving member26) is intended to slide within the “knuckle” (e.g., cylindrical engaging member30) as enclosure cover14is slide along the longitudinal direction of enclosure housing12. InFIG.6, cylindrical receiving member26comprises a curved outer bearing surface32that extends about 180 degrees around from distal end24of lip22as shown. Those skilled in the art will appreciate that the angle that outer bearing surface32extends may be somewhat greater to or less than 180 degrees but primarily sufficient to receive and allow articulation of cylindrical receiving member26relative to cylindrical engaging member30. Cylindrical receiving member26may be a rolled sheet panel as depicted or also a solid cylindrical piece. InFIG.7, cylindrical engaging member30comprises a curved inner bearing surface34that extends at least greater than about 180 degrees from side28of enclosure cover14. Inner bearing surface34of cylindrical engaging member30articulates directly with outer bearing surface32of cylindrical receiving member26and allows enclosure cover14to pivot around a central axis of cylindrical receiving member26, thereby causing enclosure cover14to swing open or close relative to enclosure housing12. Additionally, the articulation of inner bearing surface34with outer bearing surface32also allows enclosure cover14to move longitudinally relative to enclosure housing12. Flange21of cylindrical receiving member26may serve as a stop to prevent enclosure cover14from longitudinally traversing therebeyond. Curved inner bearing surface34must extend at least greater than 180 degrees around to adequately secure cylindrical engaging member30to cylindrical receiving member26and provide their relative articulation. The outer diameter of cylindrical receiving member26may vary so long as it allows for matching engagement with the inner radius of cylindrical engaging member30and proper articulation between both components. Accordingly, it can be seen that this invention provides for enclosure assembly10that offers the flexibility for enclosure cover14that can function to both swing open and/or slide open either partially or be removed completely from enclosure housing12for access to space18within the enclosure housing12as a result of the engagement and articulation of cylindrical receiving member26with cylindrical engaging member30. Additionally, it can be seen that attachment system16of the present invention provides for two degrees of freedom, namely longitudinally translation and axial rotation of cylindrical receiving member26relative to cylindrical engaging member30. The longitudinally translation and axial rotation of cylindrical receiving member26relative to cylindrical engaging member30may also occur simultaneously and not necessarily in separate discrete movements. Turning now toFIGS.8-11, a second example embodiment of the leafless joint apparatus is depicted. Once more the leafless joint apparatus or attachment system disclosed herein can act as a joint or interface between enclosure housing12and enclosure cover14.FIG.8depicts an example of enclosure cover14being in an open position via a sliding procedure.FIG.9illustrates an example of enclosure cover14being in an open position via a pivoting procedure.FIG.10illustrates an example of enclosure cover14being detached from enclosure housing12.FIG.11illustrates an assembly procedure that can reduce costs of manufacture and inventory. Referring specifically toFIG.8, with regard to the leafless joint apparatus, enclosure cover14is illustrated to be in an open position (e.g., exposing an interior of enclosure housing12) after enclosure cover14is slid in longitudinal direction82in accordance with certain embodiments of this disclosure. Such can be facilitated by tracks84situated on opposites sides of enclosure housing12. Tracks84extend in longitudinal direction82and provide a constrained structure by which enclosure cover14can slide open or closed. Contact between tracks84and elements of enclosure cover14can ensure that enclosure cover14can only move parallel or anti-parallel with longitudinal direction82. This contact can be mated in any suitable way, and can include one or more interior tabs (not shown, but see tabs15aand15bofFIG.1) on an inner surface of enclosure cover14and/or contact with pintel88(e.g., that makes contact with an underside of tracks84). At one side of track84, curved portion86can exist. Curved portion86can provide multiple functions. First, curved portion86can function as a “knuckle” and can mate with pintel88in that regard. Such allows the joint to pivot or hinge, as is further discussed in connection withFIG.9. Second, curved portion86can further function as a stop to prevent enclosure cover14from sliding beyond the fully closed position. In other words, pintel88cannot slide passed curved portion86in a direction anti-parallel to longitudinal direction82. On the opposite end of track84, in some embodiments, a stop element (not shown, but see element90ofFIG.9) can exist to prevent enclosure cover14from sliding off tracks84. For instance, when fully open, pintel88(or another element) can contact stop element90to prevent further movement in longitudinal direction82. Unlike with the first embodiment (e.g.,FIGS.1-7) of the leafless joint apparatus in which continual sliding eventually allows detachment of enclosure cover14, in this embodiment, detachment is accomplished according to a different mechanism, which is further detailed in connection withFIG.10. Thus, in this embodiment, if there is not enough space to slide enclosure cover14in longitudinal direction82a sufficient amount to provide the desired level of accessibility, then enclosure cover14can still be removed by leveraging space in a different direction. Further, enclosure cover14might also pivot open, which leverages yet another region of space for clearance, as illustrated with reference toFIG.9. InFIG.9, with regard to the leafless joint apparatus, enclosure cover14is illustrated to be in an open position (e.g., exposing an interior of enclosure housing12) as enclosure cover14is pivoting at the back wall of enclosure housing12in accordance with certain embodiments of this disclosure. Such can be facilitated by pintel88rotating within curved portion86(seeFIG.8). In some embodiments, enclosure cover14, once at least partially open according to the pivoting procedure, is prevented (e.g., flaps on the back side of enclosure cover14that contact curved portion86) from sliding in longitudinal direction82until changed to the closed position or state. Likewise, in some embodiments, once at least partially open according to the sliding procedure (e.g., illustrated inFIG.8), the aforementioned interior tabs of enclosure cover14, or another element that contacts tracks84can prevent enclosure cover from pivoting open until changed to the closed position or state. It is further observed that, while curved portions86can operate as knuckles, these knuckles do not comprise a hollow tube that runs the length of the joint, as is the case with typical hinge joints. Rather, curved portions86are limited to the placement of tracks84, and therefore the cover slides in longitudinal direction82that differs in orientation from the first embodiment of leafless joint apparatus. InFIG.10, with regard to the leafless joint apparatus, enclosure cover14is illustrated to be detached from enclosure housing12according to a detachment procedure in accordance with certain embodiments of this disclosure. Such can be facilitated due to cut92in tracks84. As noted previously, during the sliding procedure, pintel88contacts the underside of tracks84, thereby preventing the enclosure cover14from being detached or otherwise moving in normal direction94. In some embodiments, normal direction94can be orthogonal to longitudinal direction82. However, once the sliding procedure is initially started such that pintal88moves a sufficient amount in longitudinal direction82to coincide with cut92, enclosure cover14can now be detached in normal direction94as pintel88transitions through cut92. It is appreciated that, depending on implementation, cut92can be situated at any position along tracks84, including a position that coincides with the closed state such that from the closed state, the detachment procedure is available without first performing all or a portion of the sliding procedure. As illustrated, cut92can have tapered walls such that pintel88can be easily navigated through cut92, but otherwise would easily continue along tracks84in the longitudinal direction82depending on the direction of forces applied by the operator to enclosure cover14. Reattaching enclosure cover14can be provided by sliding pintel88through cut92in the opposite of normal direction94. Hence, the design of leafless joint apparatus can be configured to removably attach enclosure cover14to enclosure housing12. Further, leafless joint apparatus can be configured to perform (i) a detachment procedure in which the enclosure cover detaches from the enclosure housing (e.g., seeFIG.10), (ii) a pivoting procedure in which the enclosure cover pivots at the back wall, exposing the volume of space (e.g., seeFIG.9); and (iii) a sliding procedure in which the enclosure cover slides along the top side of the enclosure housing, exposing the volume of space (e.g., seeFIG.8). In some embodiments, leafless joint apparatus can be configured to concurrently enable all or a portion of these different procedures. For example, initially assuming the closed state, leafless joint apparatus can concurrently facilitate the sliding procedure, the pivoting procedure, or, in some embodiments, the detachment procedure. In some embodiments, the detachment procedure is first prefaced with the sliding procedure, either by transitioning beyond the fully open state in order to detach (e.g., seeFIGS.4A or4B) or by transitioning to a partially open state that coincides with the location of cut92(e.g., seeFIG.10). With reference now toFIG.11, described is an assembly technique that can reduce manufacturing and/or inventory costs in accordance with certain embodiments of this disclosure. As illustrated, enclosure housing12can comprise front panel95, back panel96, two side panels97and98and bottom panel99. One technique for assembly can be to use pop rivets as follows. Align front panel95and back panel96with bottom panel99according to locations of the pop rivets, but do not pull or activate the pop rivets. Next, align side panels97and98to bottom panel99according to locations of the pop rivets. Once all the panels are aligned, pull or activate all pop rivets to secure all panels in place. Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Thus the scope of this invention should be determined by the appended claims and their legal equivalents. | 19,619 |
11859423 | DETAILED DESCRIPTION Aspects of the system and methods are described below with reference to illustrative embodiments. The references to illustrative embodiments below are not made to limit the scope of the claimed subject matter. Instead, illustrative embodiments are used to aid in the description of various aspects of the systems and methods. This description, made by way of example and reference to illustrative reference, is not meant to be limiting as regards any aspect of the claimed subject matter. Turning toFIG.1, an embodiment of a counterbalance mechanism100for use with a lift door102is illustrated. Conventionally, counterbalance mechanisms100(also referred to herein as “counterbalance systems” or “lift systems”) are mounted directly above the lift door102to which they are attached. Lift doors102are commonly used for cargo trailers, garage doors and numerous other applications as the door is conveniently lifted up and out of the way to open the doorway. In a typical lift system, there are one or two torsion springs104disposed around a single torque shaft that spans the width of the doorway. In this illustrated embodiment, the counterbalance mechanism100includes an adjustable length torque shaft106that can be customized to fit a variety of doorways without requiring cutting of the torque shaft106at installation. In embodiments, the adjustable length torque shaft106is comprised of two outer torque shafts108and one middle torque shaft110with the two torsion springs104disposed around the outer torque shafts108. Here, the middle torque shaft110has a smaller diameter than the outer torque shafts108and can be inserted into ends of the outer torque shafts108to form the full adjustable length torque shaft106. Length of insertion of the middle torque shaft110into the outer shafts can be selected to determine the overall length of the adjustable length torque shaft106. The customizable nature of the adjustable length torque shaft106allows for use with a variety of lift doors102and the ability to disassemble the adjustable length torque shaft106and ship in its component parts, two outer torque shafts108and a middle torque shaft110, greatly reduces shipping and storage costs. As shown inFIG.1, the counterbalance mechanism100has cable drums112on each end of the adjustable length torque shaft106. Cables114are connected from each cable drum112, to the corresponding side of the lift door102so that as the cables114wrap around the cable drum112, the attachment points on the door102are lowered or raised, opening or closing the door102depending upon the style of door. For example, in a roll-up style of door, the cables114attach at the bottom of the door102so that as roll-up door is lifted and the bottom corners raised, the cables114spool onto the cable drums112. Conversely, when a roll-up door is lowered, the cables114unspool from the cable drum112. Turning now toFIGS.2A and2B, the counterbalance mechanism100will be described herein generally with respect to a ramp door style of lift door. However, it can also be used with a roll up door style of lift door. As seen here, in a ramp door102, the cables114are attached at the corners of what will be the top of the door102when the door102is in the closed position. As the ramp is raised, rotation of the torque shaft106will wrap the cables114around the cable drums112, shortening the length of cable between the cable drums112and the corner of the door102. The tension on the cable from the torsion spring104pulls the top of the ramp door102toward the counterbalance mechanism100and the top of the door frame116, offsetting the weight of the ramp door102. As the door102is lowered, the torque shaft106rotates in the opposite direction, unspooling the cable from the cable drums112and again, the torsion spring104on the torque shaft106offsets the weight of the door as the ramp door102is lowered. While the counterbalance mechanism100is shown inFIG.2Afor illustration purposes, in a typical system, the counterbalance mechanism100is installed inside the cargo trailer or doorway as shown inFIG.2B. FIG.2Billustrates an embodiment of the counterbalance mechanism100installed over a door frame116in an interior of a truck. Installation in the interior of the truck or garage protects the counterbalance mechanism100from weather and interference. The cables114can extend beyond the truck to offset the weight of the lift door102and facilitate gradually lowering or raising the lift door102. Turning once again toFIG.1, in the depicted embodiment of the counterbalance mechanism100, the torsion springs104are installed on the outer torque shaft108, one on each end of the outer torque shafts108, and the outer ends of each torsion spring104are operably fixed to mounting brackets118that attach to the door frame116or wall. As discussed in greater detail below, in embodiments, the torsion springs104are fixed to the mounting brackets118, where the bracket holds one end of the torsion spring104in a fixed position when the torque shaft106rotates with opening and closing of the lift door102. The opposite end of the torsion spring104is connected to, and rotates with, the outer torque shaft108. This rotation of the outer torque shaft108increases tension in the torsion spring104when it rotates in a first direction and releases tension in the torsion spring104when it rotates in the opposite direction. In a ramp door102, the torque shaft106rotates to increase the spring tension as the ramp door102lowers so that the force of the torsion spring104slows the lowering of the ramp door102, offsetting the weight of the door. The bias of the spring offsets the weight of the door102, at least in part, assisting in controlling the lowering of the ramp door102. Conversely, as the ramp door102is raised and the weight of the ramp door102supported by the cables114decreases, the torque shaft106rotates in a direction to reduce the tension on the torsion springs104. Here, the bias of the spring offsets the weight of the door102, assisting to lifting the door102into place and holding it in a closed position. As shown inFIG.1, counterbalance mechanisms100typically include a torque shaft106that spans the width of the door, supported on each side by a mounting bracket. Spanning the door allows the cables114to lift the door without blocking the entryway. Using a single torque shaft106allows for the use of two mounting brackets118, one each side of the door102, for a stable system. In the embodiment shown inFIG.1. The counterbalance mechanism100includes a bearing assembly120that allows the torque shaft106to rotate once seated in the mounting brackets118. In other embodiments, the bracket contains an integrated bearing, through which the torque shaft106is free to rotate. As discussed above, there are problems and limitations presented by the traditional counterbalance system. One problem presented by the traditional system is that the torque shaft106must be a fixed length that matches the width of the lift door102on which it is installed. This can result in prolonged storage of multiple lift systems with various length torque shafts. In addition, torque shafts are long, narrow and unwieldy for shipping, increasing shipping costs. Many manufacturers currently ship their lift systems preassembled with the components all attached to the torque shaft. Because the torque shaft is a fixed length and sized to span the entire width of the door it is designed to lift, the resulting shipping containers are awkwardly sized as most shipping containers are significantly longer than they are wide. These types of shipping containers are expensive to ship. To resolve the problem of multiple counterbalance systems with varying length torque shafts, distributors can sell a counterbalance mechanism100sized for a wide door, with the intent that their customers will cut the torque shaft down to the width of their particular door during installation. The consumer has to alter the system to the desired length themselves, an arduous process that will require that the consumer either to pay for a professional installer or acquire the costly equipment and devote the manpower to install the counterbalance system themselves. Of course, anytime the consumer is asked to cut down the torque shaft there is also the potential for a miscut or mismeasurement, causing wasted material and time, as well as consumer frustration and even potential injury. The counterbalance mechanism100described herein solves these problems through an adjustable length torque shaft106. In embodiments, the adjustable length torque shaft106can be shipped in its component pieces, two outer torque shafts108and a middle torque shaft110, resulting in more reasonably sized shipping containers and reduced shipping fees. The configuration of the adjustable length torque shaft106allows a distributor or consumer to easily assemble the torque shaft106for installation and eliminates the need to cut the shaft. The ease of assembly greatly reduces the complexity of installation, reducing or eliminating special tools and potential mistakes and injuries. Finally, distributors can replace stocks of multiple counterbalance mechanisms with just the counterbalance mechanism100described herein as it can be used with a variety of door widths. Referring now toFIGS.3and4, a wire frame of an embodiment of a counterbalance system with an adjustable length torque shaft106is illustrated.FIG.3shows the counterbalance system with torsion springs104in place, whileFIG.4removes the torsion springs104to better show the adjustable length torque shaft106. In an embodiment, the adjustable torque shaft106is made of three portions, two outer torque shafts108and one middle torque shaft110. In an embodiment, the middle torque shaft110has a narrower diameter than the outer torque shafts108. The outer torque shafts108can be standard sized for use with industry standard torsion springs104and cable drums112. Maintaining standard sizing of the outer shafts would enable the adjustable length torque rod to be used interchangeably with traditional counterbalance systems, limiting expenses in manufacturing, assembly and installation of the described counterbalance mechanism100. This has the additional advantage of facilitating use of the adjustable length torque shaft106and counterbalance mechanism100to repair or replace already installed counterbalance systems. In the depicted embodiment, the ends of the middle torque shaft110are inserted into each of the outer torque shafts108to form the complete adjustable length torque shaft106. The middle torque shaft110is positioned between, and inserted into, the right and left outer torque shafts108, but is not necessarily located precisely at the midpoint between the outer torque shafts108. In embodiments, the outer torque shafts108can be made of steel or any other suitable material. In an embodiment, the outer torque shafts108are approximately 1 inch in diameter; however, the counterbalance mechanism100can include torsion shafts with diameters greater or less than 1 inch. Similarly, the middle torque shaft110can be made from steel or any other suitable material and have a diameter of ¾ inch; however, middle shaft can have a diameter of greater or less than ¾ inch. In embodiments, the middle torque shaft110is held in place through a set of bushings. An internal bushing122is located at each end of the middle torque shaft110and acts as the interface with the outer torque shafts108, potentially reducing vibration and allowing for independent rotation of the middle torque shaft110and the two outer torque shafts108. Two flanged bushings124are positioned on the middle shaft to control insertion of the middle torque shaft110into each of the two outer torque shafts108. The internal and flanged bushings can allow for rotation and provide support for the interface of the middle torque shaft110and the two outer torque shafts108. In embodiments, the internal bushings122can be omitted and the middle torque shaft110and two outer torque shafts108can be connected using just the flanged bushings124. In this embodiment, the flanged bushings124can be sufficiently long to establish a solid connection. In embodiments, the flanged bushings124can be greater than 2 inches in length. In still other embodiments, the middle torque shaft110and two outer torque shafts108can be connected via pins, clamps or other means to ensure that the shafts all rotate in unison. Referring toFIG.5, an embodiment of a middle torque shaft110with bushings is shown in a wire frame view. In the depicted embodiment, the middle torque shaft110has a pair of bushings at or proximate to each end. As shown, the internal bushings122are inserted into the end of the middle torque shaft110, with a lip of the internal pushing extending from the end of the middle torque shaft110. The internal bushing122is sized to insert into an end of the outer torque shaft108. The middle torque shaft110is inserted into the flanged bushings124to a desired position to control insertion of the middle torque shaft110into the outer torque shafts108. Here, the lip or flange of the flanged bushings124are larger in diameter than the interior of the outer torque shaft108to prevent the middle torque shaft110from sliding too far into the outer torque shafts108. The flanged bushings124can be moved to change the length of the assembled adjustable length torque shaft106. Turning toFIGS.6and7, in the depicted embodiment, the potential positions of the flanged bushing124are illustrated to vary the length of the adjustable length torque shaft106.FIG.6depicts an end view of an embodiment of an adjustable torque shaft106with a flanged bushing124close to the internal bushing122. In this embodiment, the outer torque shafts108would not cover much of the middle torque shaft110, so the adjustable torque shaft106would be relatively long. In contrast, inFIG.7, the location of the flanged bushings124can be adjusted to allow for the outer torque shaft to cover a large portion of the middle torque shaft110. In this embodiment, the adjustable torque shaft106would be significantly shorter than that depicted inFIG.6. While the depicted embodiment includes the internal and flanged bushings124at both ends of the middle torque shaft110, it is possible to fix the middle torque shaft110to one of the outer torque shafts108on one side, allowing for the flanged bushing124and adjustment of length on only one side of the middle torque shaft110. The embodiment shown simplifies the counterbalance mechanism replacement process because a user can adjust the length of the overall torque shaft106by adjusting the location of the flanged bushing124to match the length of torque shaft being replaced rather than having to physically trim down a new torque shaft. This adjustable length torque shaft106can provide the stability and structure of a torque shaft spanning the width of the door102without many of the shortcomings of the fixed length torque shafts used in conventional systems. While the interface as described using simple bushings to connect the middle torque shaft110to the outer torque shafts108, a variety of bearings, bushings, and other connection means are contemplated. Turning now toFIG.8, an embodiment of the middle torque shaft110and an outer torque shaft108with the connection made by an internal bushing122and a flanged bushing124is depicted. In this embodiment, a user shifts the location of the flanged bushing124to adjust the length of the adjustable length torque shaft106. Use of the bushings can dampen vibration where the parts of the torque shaft106connect. In addition, the illustrated embodiment can allow for independent rotation of the two outer torque shafts108and the middle torque shaft110. As described in greater detail below with respect to the slack problem, where the length of the cables114is unequal between each side of the counterbalance mechanism100. When the cables114are unequal, the door102may not open or close completely or operate smoothly. In a system with a fixed torque shaft, it is difficult to adjust the cable length. However, in the illustrated embodiments, cable length can be adjusted by rotating just one of the outer torque shafts108and its attached cable drum112. Because the two outer torque shafts108can be rotationally decoupled, one cable can be adjusted without impacting the other cable. Referring toFIG.9, a wire frame view of an embodiment of a counterbalance mechanism100shows a torsion spring104disposed on an outer torque shaft108. The torsion spring104is attached to a bearing housing and extends along the adjustable torque shaft106towards the center of the middle torque shaft110. In the depicted embodiment, two torsion springs104are utilized and each torsion spring104is fixed to its own bearing housing on opposite ends of the adjustable length torque shaft106. However, other embodiments can use a single torsion spring104. In this embodiment, the bearing housing is seated in the mounting bracket when installed in a lift door102. A bearing in the bearing housing allows the outer torque shaft108to rotate freely when the bearing housing, and its attached torsion spring104, are fixed to the mounting bracket, shown inFIG.10. As depicted, the torsion springs104on each outer torque shaft108are fixed at the end proximate to the cable drums112. In this embodiment, the torsion springs104are only operationally fixed at one end to create the rotational movement of the adjustable torque shaft106that decompresses or compresses the spring when the lift door102is opened or closed. In embodiments, a winding cone126can be a solid, diecast piece of metal with a hole through its center configured to receive the adjustable torque shaft106. In embodiments, a winding cone126can also have one or more bolt holes configured to receive a bolt. In these embodiments, the bolt hole would face a direction perpendicular to the direction of the adjustable length torque shaft106so that when a bolt was threaded through the bolt hole it would clamp onto the adjustable torque shaft106, affixing the winding cone126to the adjustable torque shaft106. The winding cones126can be made of steel, aluminum, or any other suitable material. In the depicted embodiment, the end of the torsion spring104that is not attached to the winding cone126is affixed to the bearing housing. In this embodiment, winding cones126can have one or more integrated slots around its circumference, oriented so that each slot's opening faces a direction perpendicular to the direction of the adjustable torque shaft106. These slots enable the manual winding of the torsion spring104. Turning toFIG.10, a perspective view of an embodiment of a counterbalancing mechanism illustrates a bearing assembly120that connects the adjustable torque shaft106to the mounting brackets118. In this embodiment, the counterbalance mechanism100includes an integrated bearing assembly120that facilitates installation, repair and replacement of lift systems. Traditional systems frequently utilize mounting brackets118with integrated bearings. The mounting brackets118are the connection points between the lift system and the wall or truck interior on which the system is placed. The mounting brackets118hold one end of the torsion spring104in a fixed position and also suspend the mechanism above the door102at a distance from the surface from which it is attached. This is so the mechanism is free to rotate without contacting the door or wall surface. The torque shaft106runs through these bearings in the mounting brackets118so that the torque shaft106can rotate while the brackets remain fixed. Because the bracket contains an integrated bearing, it must be attached to the torque shaft106of the lift system at the time of manufacture. Because the brackets with the integrated bearing are attached to the counterbalance mechanism100at the time of manufacture, the entire counterbalance mechanism100is connected to the bracket as it is being installed on the wall or truck interior. This creates difficulties for the installer because the entire weight of the lift system must be supported while the bracket is attached to the wall or truck interior. This requires positioning the lift system at the top of the door102, typically above the head of the installer. Traditionally for applications of the system in cargo trucks, the bracket is welded to the interior wall of the cargo area. Thus, installation of a traditional system requires two laborers. One laborer welds each bracket into place while the other must support the weight of the system while the welding is completed. Alternatively, the bracket with the system attached can be welded to the interior wall before the truck's cargo area is assembled. For this installation method, the truck wall is placed flat, and the system is welded into place at some time prior to the truck wall being lifted into a vertical position. Although this method requires only one laborer, the attached system adds weight to the truck wall, making it more difficult to raise into position. Additionally, if a system breaks or otherwise requires replacement, the two-laborer installation method described above would need to be utilized. In the embodiment illustrated inFIG.10, the bearing assembly120allows the shaft to turn freely during the opening or closing of the lift door102. As shown in the depicted embodiment, a bearing assembly120is adjacent to each the cable drum112on the adjustable torque shaft106. The bearing assembly120can be comprised of a bearing housing and a bearing. In embodiments, the bearing housing can be a solid, diecast piece of metal with a hole through its center configured to receive a bearing. In the depicted embodiment, the bearing housing can have one or more bolt holes about its circumference configured to receive a bolt to enable the attachment of the bearing housing to a mounting bracket. When the mechanism is in operation, the bearing housing remains fixed to the mounting bracket, allowing the adjustable torque shaft106, and elements attached to the adjustable torque shaft106, to rotate freely, enabled by the bearing. The bearing housing can have a connection point configured to receive a torsion spring104on a side of the bearing housing opposite the side closest to the cable drum112. The bearing assembly120can be made of steel, aluminum, or any other suitable material. The cable drums112can have a connection point configured to receive a cable114, and a notch in the outer edge of the drum112to guide the cable114onto the inner portion of the cable drum112. The cable drums112can have grooves about their circumference to guide the wrapping of a cable114. The cable drums112can be made from steel, aluminum, or any other suitable material. In turning toFIG.11, shows the end of the counterbalance mechanism100in place, in a mounting bracket. In another embodiment, the counterbalance mechanism100described herein includes a universal bracket separate from the bearing assembly120, where the bracket has uniquely shaped receiving holes so that the brackets can be installed separately from the rest of the system and receive a variety of different mechanisms. A universal bracket separate from the bearing assembly120would allow for easier installation utilizing fewer laborers than what is needed to install a traditional system. Additionally, a universal bracket separate from the bearing would be able to accept different systems with a range of different bolt configurations. In particular, a universal bracket separate from the bearing could even accept a bracket with integrated bearings. This would allow for easier replacement of broken systems with systems from a variety of different manufacturers. It should be noted that while bolts are depicted to secure the mounting bracket and other features, other connection means can be used, such as screws, adhesives, or other suitable methods. Turning once again toFIG.10, the depicted embodiment shows that the outer torque shafts108extends outwards past the bearing assembly120to a cable drum112on each end of the adjustable torque shaft106. In this embodiment, a cable is attached to each cable drum112with the other end of each cable attached to the lift door102as shown inFIG.2A. The torsion springs104should now support the weight of the lift door102via the cables114. Referring now toFIGS.12A and12B, another problem can arise in certain lift systems, including but not limited to, ramp doors. When a counterbalance mechanism100is used to offset the weight of ramp doors, the door102may become have problems when opening or closing if the cables114become uneven. In typical operation, the lift door102is supported by both cables114evenly. If the cables114do not work in unison and one cable is longer than the other, then the door may not close completely and the slack in the cable can unwind from the drum. The extra or slack cable can interfere with or get tangled in the mechanism and the lift door. This is a challenging issue to fix because of the rotationally dependent nature of the cable drums112of the counterbalance lift door system created by the use of a singular torque shaft. This phenomenon is known as, and will be hereto referred to as, slack or a slack problem. FIG.12Ashows a lift door system with a slack problem. Here, the cable on the right side of the illustration is longer than that on the left, causing an uneven ramp. When the door102is has a slack problem, the door102may become stuck in a half open position. As the cables114become unequal, the door102is no longer parallel to the ground because the weight from the door102shifts and the side with the longer cable, is lower than the other side. This causes the cable, and, thus, the torsion spring104of the lower side to be under more tension. In traditional systems, this problem is exacerbated by use of the single elongated torque shaft. The single elongated torque shaft of traditional systems has rotationally coupled cable drums112and therefore adjusting the cable via the cable drums112and torque shaft would effect both cables114equally. There are multiple reasons why cables114become uneven including, but not limited to, improper installation or repair, stretching of a cable or even cargo trailer being on uneven ground. In the described counterbalance mechanism100, where the outer torque shafts108can rotate independently, the problem of slack can be resolved by rotating a single outer torque shaft108to take up the slack in the cable. As described above, the middle torque shaft110is connected to the two outer torque shafts108via bushings, and while these bushings provide support to the adjustable length torque shaft106and provide the connection to stabilize the torque shafts, the bushings do not lock the outer torque shafts108together such that the entire shaft rotates together. As a result, the middle torque shaft110allows the outer torque shafts108to rotate without exerting force on the other outer torque shaft108. Therefore, the adjustable length torque shaft106allows the cable drums112to rotate independently of one another. This independent rotation can be used to solve the slack problem as shown inFIG.12B. While for purposes of simplicity of explanation, illustrated methodologies are shown and described as a series of blocks. The methodologies are not limited by the order of the blocks as some blocks can occur in different orders and/or concurrently with other blocks from that shown and described. Moreover, less than all the illustrated blocks may be used to implement an example methodology. Blocks may be combined or separated into multiple components. Furthermore, additional and/or alternative methodologies can employ additional, not illustrated blocks. Referring now toFIG.13, an embodiment of a method for installing an adjustable length counterbalance mechanism1300is depicted. At step1302, mounting brackets118can be installed, one at the top of each side of the doorway. If the counterbalance mechanism100is being installed in an existing lift door system, mounting brackets118may already be in place and this step can be omitted. It may be particularly advantageous to use the adjustable length torque shaft106to replace the counterbalance mechanisms in existing system because of its flexibility and easy installation. At step1304, the torsion springs104should be positioned on the outer torque shafts108as shown inFIG.9. The torsion spring104is operably fixed to the torque shaft106via the winding cone126and can the opposite end of the torsion springs104can be fixed to the bearing housing. In embodiments, steps1304through1308are performed at the manufacturer or at the distributor rather than at the final installation of the counterbalance mechanism100. The assembled counterbalance mechanism100with adjustable length torque shaft106can be shipped as assembled and ready for installation onto the mounting brackets. In other embodiments, the counterbalance mechanism100can be shipped with the middle and outer torque shafts108disassembled, but the torsion spring104, bearing housing and cable drum112already installed on the outer torque shafts108. At step1306, a cable drum112is fixed to the distal end of each outer torque shaft108such that when the outer shafts are positioned over the doorway, the cable drums112will be adjacent to the sides of the doorway, leaving the doorway itself clear. Each of the cable drums112are connected to the outer torque shafts108so that the cable drum112will rotate along with the outer shaft to which it is connected. Again, this step can be performed at the manufacturer or distributor in advance of installation in the doorway. At step1308, the adjustable length torque shaft106is assembled from the middle shaft and each of the outer shafts. The flanged bushings124are positioned on the middle shaft to control the amount of the middle shaft that is inserted into each of the outer shafts. By controlling the length inserted, the length of the overall shaft is controlled. Once the flanged bushings124are positioned, the middle shaft is inserted between the two outer shafts and the adjustable length torque shaft106is assembled. An embodiment of the assembled shaft is shown inFIGS.1and3and is ready to be attached to the mounting brackets118. Alternatively, the embodiment of the counterbalance mechanism100can be pre-assembled by the manufacturer. The installer can simply adjust the position of the flanged bushing124to customize the length of the torque shaft106for installation on a particular lift door102. At step1310, the adjustable length torque shaft106can be lifted into place and positioned in the mounting brackets118above the doorway. As discussed with respect toFIG.11, the bearing housing can be fixed to the mounting bracket via bolts or other means to secure one end of each torsion spring104. In this embodiment, the connection between the end cone and the mounting bracket is what makes the outer end of the torsion spring104operably fixed. In step1312, in this embodiment, an end of a cable would be attached to each cable drum112and at step1314the other end of each of the cables114is attached to the respective side of the lift door102. Finally, at step1316, the winding cone126is be tightened to adjust the cable tautness and tension on the spring to properly counterbalance the weight of the lift door102. Referring now toFIG.14, an embodiment of a method for correcting a slack problem in a counterbalance system is depicted. At step1402, the slack problem or condition is identified. When the door102is raised or lowered, it can be apparent that the tension on the two cables114is unequal, and that one cable is longer than the other. This condition can prevent the lift door102from fully opening or closing. Once the slack problem is identified, the lift door102can be returned to its previous position at step1404, and the loose cable and the shorter cable can be identified at1406. The operator can elect to either tighten the loose cable or loosen the overly taut cable by rotating the winding cone126associated with the spring to which the selected cable is connected. Rotating the cone will rotate the selected torsion spring104and the outer torque shaft108to which it is attached. Rotating the outer torque shaft108will in turn rotate the cable drum112, spooling or unspooling the cable. Because the outer torque shaft108on one side is rotatably decoupled from the other outer torque shaft108, the slack the cable can be shortened on one side without effecting the length of the cable on the other side. Because the two outer shafts are capable of rotating independent of each other, the tension on one side can be adjusted to match the other side at step1408. What has been described above includes examples of aspects of the claimed subject matter. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the claimed subject matter, but one of ordinary skill in the art may recognize that many further combinations and permutations of the disclosed subject matter are possible. Accordingly, the disclosed subject matter is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the terms “includes,” “has” or “having” or variations in form thereof are used in either the detailed description or the claims, such terms are intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim. | 33,762 |
11859424 | DETAILED DESCRIPTION OF THE INVENTION The claimed features of the present invention brake shoe and ribbon spring can be incorporated into many window counterbalance designs. However, the embodiments illustrated show only two exemplary embodiments of the counterbalance system for the purpose of disclosure. The embodiments illustrated are selected in order to set forth two of the best modes contemplated for the invention. The illustrated embodiments, however, are merely exemplary and should not be considered limitations when interpreting the scope of the appended claims. Referring toFIG.1, in conjunction withFIG.2, there is shown an exemplary embodiment of a counterbalance system10that is used to counterbalance the sashes12contained within a window assembly14. The counterbalance system10utilizes a brake shoe housing16, a cam element18, and at least one ribbon spring20on either side of each window sash12. The brake shoe housing16engages a tilt post22that extends from the bottom of the window sash12. As the window sash12is opened and closed, the brake shoe housing16travels up and down in vertical guide tracks24. It will be understood that each window sash12typically utilizes two counterbalance systems on opposite sides of the sash12. However, for the sake of simplicity and clarity, only one counterbalance system10is illustrated. The brake shoe housing16receives the cam element18to form a brake shoe assembly25. The brake shoe assembly25rides up and down in its guide track24. The brake shoe assembly25is pulled upwardly within the guide track24by at least one ribbon spring20. The guide track24has a rear wall26and two side walls27,28. The brake shoe assembly25is sized to be just narrow enough to fit between the side walls27,28of the guide track24without causing excessive contact with the guide track24as the brake shoe assembly25moves up and down with the window sash12. The brake shoe housing16is plastic and is unistructurally molded as a single unit that requires no assembly. The brake shoe housing16is generally U-shaped, having a first arm element30and a second arm element32that are interconnected by a thin bottom section34. In the shown embodiment, the ribbon spring20selectively attaches to the first arm element30in a manner that is later described. A generally circular cam opening36is formed between the first arm element30, the second arm element32and the bottom section34. Above the cam opening36, the first arm element30and the second arm element32are separated by a gap space38. The first arm element30has a first sloped surface39that faces the gap space38. Likewise, the second arm element32has a second sloped surface41that faces the gap space38. Taken together, the first sloped surface39and the second sloped surface41diverge away from each other as they ascend above the cam opening36. The result is that the gap space38has tapered sides that lead into the cam opening36. During manufacture, the cam element18is inserted into the cam opening36by forcing the cam element18into the gap space38between the first arm element30and the second arm element32of the brake shoe housing16. When pressed into the gap space38, the cam element18spreads the first arm element30and the second arm element32apart. This is achieved by the elastic flexing of the thin bottom section34of the brake shoe housing16, which acts as a living hinge. The first arm element30has a side surface44. A receptacle46is formed in the side surface44. The receptacle46is sized to receive and retain the shaped head48of the ribbon spring20. A relief50is formed in the side surface44of the first arm element30just above the receptacle46. An inclined protrusion42is disposed in the relief50. The inclined protrusion42has an inclined surface43that extends from the surface of the relief50to a curved crown45. The shape of the inclined protrusion42enables the inclined protrusion42to selectively deform the ribbon spring20in a unique manner that is later explained. Referring toFIG.3in conjunction withFIG.2, it can be seen that the ribbon spring20is made of a wound ribbon52of steel. The ribbon spring20has a long section54with a constant running width W1. The long section54terminates at one end with the shaped head48. The shaped head48is T-shaped. That is, at the shaped head48, the running width W1 of the long section54reduces down to a narrow neck56. The narrow neck56has a width W2 that is smaller than the running width W1. The narrow neck56extends to a wider leader58. The leader58is wider than the narrow neck56but no wider than the running width W1. A U-shaped hole60is formed in the long section54of the ribbon spring20just prior to the shaped head48. The U-shaped hole60produces a flexible locking tab62within the U-shaped hole60. The flexible locking tab62is free on three sides and connected to the remainder of the ribbon spring20along a base edge64. The base edge64faces the shaped head48. Accordingly, the flexible locking tab62extends away from the shaped head48. An optional connector slot66can be formed in the long section54proximate the shaped head48of the ribbon spring20. The connector slot66is used to interconnect ribbon springs, should a window application require the use of multiple ribbon springs. Referring toFIG.4in conjunction withFIG.2, it can be seen that the shaped head48of the ribbon spring20interconnects with the first arm element30of the brake shoe housing16. The first arm element30of the brake shoe housing16is specially designed to receive both the shaped head48of the ribbon spring20and a length of the ribbon52just before the shaped head48. When the ribbon spring20is engaged with the brake shoe housing16, the shaped head48of the ribbon spring20enters the receptacle46and extends through the relief50. This aligns the U-shaped hole60and flexible locking tab62on the ribbon spring20with the inclined protrusion42on the brake shoe housing16. The width of the inclined protrusion42is generally the same as the width of the flexible locking tab62. Accordingly, as the ribbon spring20is pressed into the relief50toward the brake shoe housing16, the inclined protrusion42will deform the flexible locking tab62away from the brake shoe housing16. Referring toFIG.5in conjunction withFIG.1,FIG.2andFIG.4, it will be understood that when the sash12is closed, the brake shoe assembly25is in an unlocked configuration. In the unlocked configuration, the brake shoe assembly25is free to slide up and down in the vertical guide track24. The ribbon spring20is attached to the first arm element30of the brake shoe housing16. In the unlocked configuration, the ribbon spring20pulls upwardly on the brake shoe housing16. This causes the brake shoe housing16to have a rotational bias in the clockwise direction as it travels up and down in the guide track24. To prevent the brake shoe housing16from cocking in the clockwise direction, the second arm element32is provided with an extension68. The extension68elongates the second arm element32and provides more surface contact with the side wall28of the vertical guide track24. This extended contact inhibits the brake shoe assembly25from binding in the guide track24. In the unlocked configuration, the ribbon spring20is oriented so that it is not pressed against the inclined protrusion42. As a result, the inclined protrusion42does not deform the flexible locking tab62in the center of the U-shaped hole60. FIG.6shows the brake shoe assembly25in a locked configuration. Referring toFIG.6in conjunction withFIG.1andFIG.2, it can be seen that when the window sash12is tilted inwardly, the tilt post22of the window sash12causes the cam element18to turn inside the cam opening36. The cam element18spreads the first arm element30apart from the second arm element32of the brake shoe housing16. As the cam element18spreads the brake shoe housing16, the brake shoe housing16flexes in its bottom section34. The first arm element30and the second arm element32are displaced and are biased against the side walls27,28of the track24. In this locked configuration, the ribbon spring20becomes biased against the inclined protrusion42. The inclined protrusion42deflects the flexible locking tab62. This causes the flexible locking tab62to stick out and engage the side wall27of the guide track24. Due to the orientation of the flexible locking tab62, the flexible locking tab62acts like a barb and dramatically increases the forces needed to slide the brake shoe assembly25upwardly within the guide track24. The result is that the brake shoe assembly25becomes locked in position within the guide track24for as long as the window sash12remains tilted. In all previous embodiments, a single ribbon spring engages the brake shoe assembly. However, if a window sash is particularly large and/or heavy, multiple ribbon springs may be ganged together. InFIG.7, it can be seen that the connector slot66in the ribbon spring20is shaped so that multiple ribbon springs, can be ganged together. The shaped head48has a narrowed neck56with a wide leader58. The narrow neck56has a width. The leader58has a wider width. This enables the shaped head48from a first ribbon spring20A to mechanically engage a second ribbon spring20B by passing the shaped head48of one ribbon spring20A through the connector slot66of a second ribbon spring20B. This gang connection can be repeated to join a plurality of ribbon springs together. It will be understood that the embodiments of the present invention counterbalance system that are described and illustrated herein are merely exemplary and a person skilled in the art can make many variations to the embodiment shown without departing from the scope of the present invention. All such variations, modifications, and alternate embodiments are intended to be included within the scope of the present invention as defined by the appended claims. | 9,854 |
11859425 | DETAILED DESCRIPTION OF THE INVENTION InFIG.1the upper deck of a car body of a double-decker rail vehicle according to the invention of the public passenger transport system is shown with a door device according to the invention in cross section. The roof14of the car body of the rail vehicle can be seen, as well as a ceiling13defining the interior toward the top, in particular the passenger compartment, of the car body. The ceiling13can also form a lower edge of a door lintel. Moreover, a first door leaf1,1′ of a double-leaf inner sliding door of the door device is illustrated—here only the left-hand door leaf for the sake of clarity. The double-leaf sliding door serves for separating two interiors from one another. In a closed position of the double-leaf sliding door, the first door leaf1is illustrated by solid lines. In an open position in the schematic view, the first door leaf1′ is sketched in dashed lines. This nomenclature also applies to further displaceable components. The first door leaf1,1′ is located in a vertical plane in which a vertical axis and a transverse axis of the car body run. An upper first guide3of the first door leaf1,1′ is arranged in the ceiling region or roof region, i.e. between the ceiling13and the roof14of the car body. The upper first guide comprises a first guide rail along which a first running body11,11′, for example a guide roller carriage, is displaceably guided. The first door leaf1,1′ is connected in a suitable manner to the first running body11,11′ via a first arm5,5′. In this schematic cross section, the first running body11,11′ is arranged in the closing direction of the first door leaf1,1′ from an open position (1′) into a closed position (1) upstream of the first door leaf1,1′, i.e. offset with respect to the first door leaf1,1′ in the vehicle transverse direction. In the opening direction, the first running body is correspondingly arranged downstream. The first arm5,5′ serves for bridging the spacing between the first running body11,11′ and the first door leaf1,1′ in the vehicle transverse direction. Moreover, in this exemplary embodiment a closed drive belt, in this case a toothed belt8, is provided in the roof region or ceiling region of the car body. The toothed belt is designed to circulate and to be wound around deflection rollers9. As set forth in more detail below, the first door leaf1,1′ and thus also the first running body11,11′ are connected to the toothed belt8via driver elements on the toothed belt8which act on the first arm5,5′. During opening or closing movements of the first door leaf1,1′, the closed toothed belt8is moved in a circulating manner around the deflection rollers. Conversely, a force is applied by the toothed belt8, which is moved in a circulating manner around the deflection rollers, onto the first door leaf1,1′ which is used in order to open and to close this first door leaf or the double-leaf sliding door. To this end, a door drive is provided, said door drive also being positioned in the roof region or ceiling region of the car body and being connected to the toothed belt8or the deflection rollers9. This is omitted in the drawings for the sake of simplicity. Naturally, these embodiments relative to the first door leaf1,1′ also apply equally to a second door leaf2,2′ of the double-leaf sliding door, as shown inFIG.2andFIG.3.FIG.2illustrates the double-leaf sliding door in the closed position,FIG.3equally in the open position. The reference numerals2,6and12in this case denote the second door leaf2, a second arm6and a second running body12in the closed position, and the reference numerals2′,6′ and12′ in this case refer accordingly to the aforementioned positions in the open position. In the closed position according toFIG.2it can be clearly identified that both respective running bodies11and12are offset in the direction of movement to the respective corresponding door leaves1and2in the vehicle transverse direction, such that they are located level with the respective other door leaf1,2and are located parallel thereto. While it is difficult to identify it in the cross sections, it is illustrated inFIG.4, which shows the door device according to the invention, that the first upper guide3for the first door leaf1,1′ is spatially separated from a second upper guide4for the second door leaf2,2′. The upper guides3,4are arranged offset to one another perpendicularly to the respective guide direction of the door leaves1,1′ and2,2′ on different sides of a plane of the door leaves1,1′ and2,2′ and thus arranged spaced apart from one another and spaced apart from the door leaf plane. Thus the door leaves1,1′ and2,2′ are not only offset in the vehicle transverse direction and thus in the direction of movement of the door leaves1,1′ and2,2′ but also offset to the respective running body11,11′ and12,12′ in the vehicle longitudinal direction and thus perpendicularly to the door leaf plane. The respective guide rails of the upper guides3and4run parallel to one another and parallel to the plane of the door leaves1,1′ and2,2′. In this case, the guide rails of the first upper guide3and the second upper guide4are arranged such that the plane of the first door leaf1,1′ and of the second door leaf2,2′ is arranged centrally therebetween, i.e. with the same spacing in each case. The respective spacings in the vehicle longitudinal direction between the door leaves1,1′ and2,2′ and their respective running bodies11,11′ and12,12′ are in turn bridged by the respective arms5,5′ and6,6′. The traction drive7with the toothed belt8and the deflection rollers9is also arranged centrally between the upper guides3,4. The vertical plane of the door leaves1,1′ and2,2′ intersects the imaginary horizontal plane, in which both guides3,4are located, centrally between the guides3,4. The axes of the deflection rollers9are located in the plane of the door leaves1,1′ and2,2′. The door leaves1,1′ and2,2′ are fastened via the arms5,5′ and6,6′ to driver elements10,10′ of the toothed belt8. These driver elements are arranged between the deflection rollers9on the portions which move in opposing directions of the toothed belt8which is wound around the deflection rollers9so that the door leaves1,1′ and2,2′ are moved and thus the inner door opens or closes. By separating the upper guides3,4and the respective horizontal and vertical offset of the door leaves1,2to the running bodies11,12thereof, the guides3,4can be of short design and thus take up less installation space in the vehicle transverse direction, which is advantageous, in particular, in the case of double-decker vehicles in the upper deck by the roof line sloping steeply to the side. | 6,692 |
11859426 | DETAILED DESCRIPTION Before turning to the figures, which illustrate certain exemplary embodiments in detail, it should be understood that the present disclosure is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology used herein is for the purpose of description only and should not be regarded as limiting. One embodiment of the present disclosure relates to an adjustable hinge assembly configured to couple a pivoting door or panel to a wall, frame, or other fixed structure. In various embodiments, the hinge assembly may include an inner plate, an outer plate configured to couple to the inner plate via two or more support fasteners that extend from the inner plate, through the door or panel, and into the outer plate. The hinge assembly may also include a slider piece, configured to fit within the door or panel and having a first slot disposed therethrough. In various embodiments, the hinge assembly may be installed within a glass panel and the slider may protect the glass from abrasive contact (e.g., metal contact from a boss feature of the outer plate, etc.) and provide a low friction surface to facilitate sliding across the interface. The hinge assembly is configured such that the support fasteners coupling the inner plate to the outer plate pass through and are supported within the first slot of the slider piece. The first slot of the slider piece may have a length that is greater than a width of a boss feature of the outer plate such that the slider, and thus the door or panel, may be adjusted relative to the inner and outer plates to accommodate varying fits and/or out-of-plumb conditions. The boss feature is configured to fit within the first slot of the slider piece. The outer plate may have a length that is greater than a length of the inner plate such that the outer plate extends to an edge of the door or panel nearest to the structure. The outer plate edge nearest the structure may be rotatably coupled at a joint to an anchor plate, which may be fastened to the structure via a plurality of fasteners. A position of the door or panel relative to the hinge may be adjusted by loosening the support fasteners coupling the inner plate to the outer plate such that the door or panel may be repositioned in a lateral direction relative to the inner and outer plates via the slider piece disposed within the panel (e.g., using a hand tool, maneuvering the entire panel to the desired alignment position, etc.). Once repositioned, the door or panel may be fixed in place through tightening of the support fasteners such that the panel is secured between the inner and outer plates at the desired position. In various embodiments, the inner plate may include a second slot disposed above the support fasteners. The second slot may be configured to receive an indicator tab coupled to the slider piece, such that a lateral adjustment of the panel within the first slot of the slider piece relative to and facilitated by the boss feature may be indicated by a corresponding position of the slider piece indicator tab within the second slot. In various embodiments, the joint formed by the rotatable coupling of the outer plate and the anchor plate may be disposed within a cutout or recess within the door or panel. In various embodiments, the outer plate may have a protruding lip that is supported within the cutout or recess within the door or panel. In various embodiments, the inner plate may include one or more gaskets along a perimeter of the inner plate disposed between the inner plate and the panel or door such that the inner plate is supported on the door or panel by compression of the gaskets resulting from tightening of the support fasteners. In various embodiments, the outer plate may include one or more gaskets disposed between the outer plate and the panel or door such that the outer plate is supported on the door or panel by compression of the gaskets resulting from tightening of the support fasteners. In various embodiments, the one or more gaskets may protect the panel or door from abrasive contacts (e.g., contact with the support fasteners, contact with the inner and/or outer plate, etc.). In various embodiments, the hinge assembly may include one or more cover assemblies, wherein the one or more cover assemblies may include, but are not limited to, an inner cover, an outer cover, and a door-side cover. In various embodiments, the inner cover may be fitted over the inner plate to conceal the support fasteners, slider piece indicator tab, and gaskets. In various embodiments, the outer cover may be fitted over the outer plate to conceal the support fasteners. In various embodiments, the door-side cover may be fitted over the anchor plate to conceal the fasteners disposed therein. In various embodiments, the cover assembly may be customized or selected to fit a particular aesthetic finish (e.g., chrome finish, shiny, matte, matte black, varying colors and/or gloss, etc.) The present disclosure provides an adjustable hinge assembly that enables adjustment of a pivoting door or panel on a side of the hinge that is coupled to the door or panel. Positional adjustment of the door or panel on the hinge-coupled side enables the door or panel to be installed last within a structure, separate from the hinge itself. Accordingly, the door or panel may be installed in a correct position from initial coupling, which prevents risk of potentially damaging opposite side strike (i.e., striking of the door or panel on a door jamb, threshold, and/or surrounding structural framework). Furthermore, the adjustable hinge assembly facilitates adjustment of the door or panel relative to the hinge without requiring repeated or iterative repositioning or adjustment, as is typically required with traditional installation methods for pivoting doors or panels, which frequently involve shimming and/or other jamb or mount-side adjustments. The adjustable hinge assembly also provides flexibility of design, as the adjustable hinge may be configured to adapt to a variety of pivoting panels or doors without requiring a full-length hinge or obtrusive assemblies to correct out-of-plumb conditions or to accommodate varying fit conditions. Accordingly, the provided adjustable hinge assembly enables simple, intuitive, and streamlined installation/adjustment of a pivoting door or panel with minimal risk to the pivoting door or panel. Referring generally to the figures, an adjustable hinge assembly may be configured to couple a pivoting door or panel (“hereinafter panel”) to a wall, frame, or other structure (hereinafter “structure”). The hinge assembly may include an inner plate, an outer plate, and an anchor plate. The anchor plate may be configured to receive a plurality of fasteners to couple the anchor plate to the structure. The outer plate, which may be rotatably coupled to the anchor plate at a joint, is positioned on an opposite side of the panel as the inner plate. In various alternate embodiments, the configuration could be swapped such that the inner plate may be rotatably coupled to the anchor plate at a joint and positioned on an opposite side of the panel as the outer plate. The inner plate and the outer plate may be coupled via support fasteners, which extend from the inner plate through a cutout in the panel to the outer plate, or vice-versa. The cutout is dimensioned such that a length of the cutout is greater than a width of the boss feature, which when loosened, the support fasteners and the coupled plates may enable adjustment of the panel relative to the hinge to accommodate varying fits and/or out-of-plumb conditions of the structure. Alternatively, during installation of the panel, the hinge assembly may be loosely coupled to the panel to allow adjustment of the panel into a desired position, after which the hinge may be anchored to the structure. Once the panel is suitably positioned, and the hinge anchor plate is secured, the support fasteners may then be tightened to fix the panel relative to the hinge. In various embodiments, this adjustability can enable streamlined panel installation (i.e., requiring a single or minimal installation attempts). For example, the hinge may enable panel installation equidistant from a floor by supporting the panel with one or more shims/installation blocks of equal height. In various embodiments, the hinge assembly may also include a slider piece, configured to fit within the cutout in the panel and having a slot disposed therethrough. The slider piece, which may be press-fit within the panel cutout, may comprise one or more low-friction materials to facilitate ease of adjustment of the hinge assembly relative to the panel. The hinge assembly is configured such that the support fasteners, which couple the inner plate to the outer plate, pass through and are supported within the slot of the slider piece. The slot within the slider piece may have a length that is greater than a width of the boss feature such that the fasteners, and thus the inner and outer plates, may be adjusted relative to the panel to accommodate varying fits and/or out-of-plumb conditions. In various embodiments, the slot within the slider may correspond to a width equal to the boss feature and the panel cutout may have a length that is greater than a length of the slider, which may enable adjustment of the panel relative to the hinge assembly, including the slider, to accommodate varying fits. In various embodiments, the inner plate or outer plate may include a second slot disposed above the support fasteners. In various embodiments, the slider piece may include an indicator tab disposed on a top portion of the slider piece. In various embodiments, the indicator tab may be coupled to slider piece. In other embodiments, the indicator tab may be integrally formed within the slider piece. In various embodiments, the second slot may be configured to receive the indicator tab such that a lateral adjustment of the panels around the boss feature may be indicated by a corresponding position of the slider piece indicator tab within the second slot. In various embodiments, the outer plate may have a length that is greater than a length of the inner plate such that the outer plate extends to an edge of the door or panel nearest to the structure. As previously described, the outer plate edge nearest the structure may be rotatably coupled at a joint to an anchor plate. In various embodiments, the joint formed by the rotatable coupling of the outer plate and the anchor plate may be disposed within an edge cutout or recess within the panel. In various embodiments, the outer plate may have a protruding lip that is supported within the edge cutout or recess within the door or panel. In various embodiments, the joint and the protruding lip may be integrally formed. In various embodiments, the outer plate and the anchor plate are rotatably coupled via a press fit assembly or one or more fasteners, and including wear resistant and low friction material which facilitate axial rotation about the joint. In various embodiments, the outer plate and the anchor plate are configured to mutually engage to enable rotation of the outer plate relative to the anchor plate. In various embodiments, the inner plate may include one or more gaskets or spacers along a perimeter of the inner plate disposed between the inner plate and the panel or door such that the inner plate is supported on the door or panel by the one or more gaskets or spacers. In various embodiments, the outer plate may include one or more gaskets or spacers disposed between the outer plate and the panel or door such that the outer plate is supported on the door or panel by the one or more gaskets or spacers. In various embodiments, the one or more gaskets or spacers may comprise one or more elastic or viscoelastic materials. In various embodiments, the hinge assembly may be coupled to a cover assembly, wherein the cover assembly may include an inner cover, an outer cover, and a door-side cover. In various embodiments, the inner cover may be configured to fit over an external portion of the inner plate to conceal exposed portions of the support fasteners, slider piece indicator tab, and gaskets. In various embodiments, the outer cover may be configured to fit over an external portion of the outer plate to conceal exposed portions of the support fasteners and/or features configured to receive or engage with the support fasteners. In various embodiments, the door-side cover may be configured to fit over an exterior portion of the anchor plate to conceal exposed portions of the fasteners disposed therein. In various embodiments, the cover assembly may be customized or selected to fit a particular aesthetic finish (e.g., chrome finish, shiny, matte, matte black, varying colors and/or gloss, etc.). In various embodiments, the cover assembly may be coupled to the inner plate, outer plate, and anchor plate via press-fit or snap-on connections. In various embodiments, at least one of the outer plate, the inner plate, and the anchor plate may have a particular aesthetic finish (e.g., chrome finish, matte, etc.) wherein portions of fasteners disposed therein remain unexposed such that a cover assembly is unneeded. Turning now to the figures and referring specifically toFIG.1, a perspective view of an adjustable hinge100is shown, according to an exemplary embodiment. As shown inFIG.1, the hinge100facilitates coupling a panel10to a structure (e.g., frame, wall, etc.) via an anchor plate105. The anchor plate105may be affixed to the structure via a plurality of fasteners110(e.g., screws, nails, etc.). In various embodiments, the panel10may be a pivoting panel or door. In various embodiments, the panel10may be a pivoting glass panel or door, such as for a shower. The panel10may be any type of panel or door configured for pivotal movement, such as in a home or building. AlthoughFIG.1shows the hinge100having three fasteners110, in various embodiments, the hinge100may include any number of fasteners110for affixing the anchor plate105to the structure. As shown, the anchor plate105is rotatably coupled to the outer plate125at a joint113, which is formed by an arm115of the anchor plate105engaging with a receiving portion (e.g., lip)120of the outer plate125. In various embodiments, the receiving portion120is disposed near an end of the outer plate125(and the joint113), which is positioned closest to an edge of the panel10when the hinge100is coupled to the panel10. In various embodiments, the arm115and the receiving portion120are mutually coupled by a fastener or pin via a press fit installation, about which the outer plate125may rotate relative to the anchor plate105. In various embodiments, the arm115and the receiving portion120may have a low friction or wear resistant material (e.g., bushing) disposed therebetween. In various embodiments, the arm115and the receiving portion120may interconnect to form a rotatable coupling at joint113. In various embodiments, joint113may include one or more rotational dampers to enable control of rotation of the hinge100at the joint113. As shown, the outer plate125is disposed on an opposite side of the panel10as an inner plate130. The outer plate125and the inner plate130are substantially parallel. The inner plate130may be coupled to the outer plate125through the panel10via support fasteners135. AlthoughFIG.1shows 2 fasteners135, in various embodiments, the hinge100may include any number of fasteners135to affix the outer plate to the inner plate. In various embodiments, support fasteners135may be screws, bolts, etc., which may be selectively tightened/loosened and having sufficient length to pass through the inner plate130and the panel10to engage with the outer plate125. The support fasteners135may pass through a cutout within the panel10such that when the support fasteners135are sufficiently loosened, lateral movement of the panel110or the slider140and the coupled plates125and130is enabled. As shown, the hinge100includes a slider piece140, which is disposed within the panel10(i.e., within the cutout), includes a groove on which the (e.g., contained within a boss feature of the outer panel125) may be supported as they pass through the cutout of the panel10. FIG.2shows a perspective view of the hinge100near the inner plate130, according to an exemplary embodiment. As shown, the inner plate130may interface with one or more gaskets145disposed between the inner plate130and the panel10, which may facilitate support of the inner plate cover onto the inner plate. In various embodiments, the one or more gaskets145may be disposed along a perimeter of the inner plate130. In various embodiments, gaskets145may form a continuous or contiguous gasket portion disposed along the perimeter of the inner plate130. In various embodiments, the outer plate125may include a continuous gasket or a plurality of gasket similar or equivalent to gasket145to facilitate support of outer plate relative to the panel10. In various embodiments, at least one of the inner plate130and the outer plate125may include one or more apertures147, which are configured to facilitate supporting and/or coupling of one or more plate covers to the inner plate130and/or the outer plate125. AlthoughFIG.2shows the inner plate130having four apertures147, in various embodiments, inner plate130and/or outer plate125may include any number of apertures147. As shown inFIG.2, the inner plate130includes a slot150disposed above the support fasteners130. The slot150may be configured to receive a portion of the slider piece140, such that lateral adjustment of the panel10relative to the hinge100may be visually indicated by a corresponding lateral position of the slider piece140within the slot150. As shown, a width155of the slot150may be the same or less than a width157between the support fasteners135. Conversely, as previously described, a length of the slot150within the slider piece140may be greater than the width157between the support fasteners135. FIG.3shows a perspective view of the slider piece140, according to an exemplary embodiment. As shown, the slider piece140includes an outer frame portion160, which defines a slot165. The slider piece140is configured to fit within a cutout in the panel10such that the frame portion160(or an outer edge of the frame portion160) interfaces and/or engages with a perimeter of the cutout in panel10. Accordingly, when the slider piece140is positioned within the panel10, the slider piece140remains stationary relative to the panel10. FIG.4shows a perspective exploded view of the outer plate125and the anchor plate105, according to an exemplary embodiment. As shown, the outer plate125may include a boss feature172, which is configured to receive support fasteners135. Furthermore, the slot165within the sliding piece140may be configured to receive the boss feature172of outer plate125, such that the support fasteners135may pass through the inner plate130, the slot165, and into the boss feature172to facilitate coupling of the inner plate130to the outer plate125. In various embodiments, the boss feature172on the outer plate125and the slot165of the slider piece140may be sufficiently sized to enact a clamping force on panel10or to prevent clamping of the panel10at the interface between the boss feature172and the slot165. In various embodiments, the panel10may have a varied thicknesses. In some embodiments, the boss feature172may be made of or coated by one or more friction resistant materials to facilitate sliding within the slot165. As shown inFIG.4, the outer plate125and the anchor plate105may be rotatably coupled via pin174and/or bushings176, which may configured to engage with the arm115of the anchor plate105and the receiving portion120of the outer plate125. In various embodiments, the slider piece140may include one or more materials having frictionless or low-friction properties to facilitate ease of lateral movement of the boss feature172therein. As shown, the slider piece140includes an indicator tab170located on a top portion of the slider piece140. In various embodiments, the indicator tab170may be coupled to the frame portion160of the slider piece140. In various embodiments, the indicator tab170may be integrally formed with the frame portion160. As evident fromFIGS.2and3, the indicator tab170may fit within the slot150of the inner plate135such that a position of the indicator tab170indicates an amount of lateral movement of the support fasteners135within the slot165resulting from adjustment of the panel10relative to the hinge100. In various embodiments, the indicator tab170may be utilized to cause adjustment of the hinge100relative to the panel10. In some embodiments, the indicator tab170may be leveraged by a tool (e.g., screwdriver) to cause lateral movement of the slider140, and thus the panel10, relative to the boss feature172, which may result in adjustment of the hinge100relative to the panel. FIG.5shows a perspective exploded view of the hinge100, according to an exemplary embodiment. As shown, the hinge100may include one or more additional gaskets and/or spacers adjacent to at least one of the outer plate125and the inner plate130. As illustrated, a gasket145may be disposed between the inner plate130and the panel10to provide support and/or to prevent abrasive contact therebetween. As shown, the gasket145may include one or more cutouts or apertures146disposed therethrough, where the apertures146are formed to have a generally complementary shape to the fasteners135and/or the indicator tab170. In various embodiments, a gasket178may be disposed between the outer plate125and the panel10to facilitate support and/or to prevent abrasive contact therebetween. As shown, the gasket178may include an elongated opening177, which may be complementary in shape to the boss feature172, and a cover portion179, which may be complementary in shape and configured to interface with the receiving portion120of the outer plate125. In various embodiments, the hinge100may include a slider spacer180, which is configured to fit within the slot165of the slider piece140. In various embodiments, the support fasteners135may pass through the slider spacer180(e.g., through one or more holes or apertures disposed therethrough) such that the slider spacer180supports the slider140. As shown, the slider spacer180may also include a cutout or recess181disposed on an upper portion of the slider space180, where the recess181is configured to accommodate sliding of the indicator tab170. The slider spacer180may additionally ensure sufficient contact between the top surface of slider140and the panel10while maintaining a gap between the outer gasket178and inner gasket145, which enables substantially free lateral movement of the slider140without compression friction, and thus the panel10, with respect to the inner and outer plates125and130, respectively. In various embodiments, the slider spacer180may be configured to move relative to the slot165of the slider piece140to facilitate adjustment of the panel relative to the hinge100. FIG.6shows a schematic representation of a side view of a panel10, according to an exemplary embodiment. As shown, the panel10includes a cutout182(e.g., slot, hole, aperture), which is configured to receive the slider piece140. In various embodiments, the slider piece140may be coupled to the panel10via a press-fit or a snap fit such that the outer frame160of the slider piece140interfaces or engages with a perimeter of the cutout182. As illustrated inFIG.6, the cutout182has a height183and a width184, which respectively correspond to a height and width of the outer frame160of the slider piece140. As shown inFIG.6, the panel10may include a second edge cutout or recess185along an edge of the panel10near the structure to which the panel10may be coupled. The recess185may be configured to receive joint113such that a perimeter of the recess185engages, interfaces with, and/or supports the receiving portion120of the outer plate125. In various embodiments, the receiving portion120of the outer plate125may be press-fit or snap fit into the recess185. FIG.7shows a perspective view of the outer plate125, according to an exemplary embodiment. In various embodiments, the hinge100may include one or more stoppers and/or dampers, which may be used in between the outer plate125and anchor plate105to avoid abrasive (e.g., metal on metal) or otherwise detrimental contact between members of hinge100. In various embodiments, the stoppers or dampers may include one or more elastic or viscoelastic materials. As shown inFIG.7, the outer plate125may be configured to receive stoppers187and190at ends192and194, respectively. In various embodiments, the stoppers187and190are configured to prevent abrasive, vibrational (e.g., noise), or other detrimental contact between members of hinge100(e.g., between the outer plate125and the arm115and/or the anchor plate105) when the hinge100is in a closed and an open position, respectively. For example, the stoppers187may prevent detrimental contact between the outer plate125and the anchor plate105and the stopper190may prevent detrimental contact between the outer plate125and the arm115. As shown inFIG.8, the stoppers187and190may include extruded elements196and198, respectively, which are configured to engage with the outer plate125and enable coupling thereto (e.g., via press-fit or friction fit). FIGS.9and10show perspective views of the hinge100, according to various exemplary embodiments. As shown, hinge100may include a cover assembly having an anchor plate cover210, an inner cover215, and an outer cover220. To conceal exposed components within the hinge100, the anchor plate cover210, the inner cover215, and the outer cover220may be coupled to exterior portions of the anchor plate105, the inner plate130, and the outer plate125, respectively. In various embodiments, each of the anchor plate cover210, the inner cover215, and the outer cover220may be configured to couple to the anchor plate105, the inner plate130, and the outer plate125, respectively, via a press-fit or snap-fit coupling through the apertures147on the plates. In various embodiments, each of the anchor plate cover210, inner plate130, and the outer plate125may include a protruding feature (e.g., ridge or rim) along an inner edge to facilitate coupling the components within the hinge100. In various embodiments, the cover assembly may conceal components within the hinge100having recesses, varied surfaces, crevices, etc. that may be difficult or time consuming to clean (e.g., fastener heads). In various embodiments, the cover assembly may provide aesthetic benefit and may be customizable based on a desired appearance of the hinge100. As shown inFIG.9, the cover assembly may include an anchor plate cover210, inner cover215, and outer cover220having a smooth, black finish. As shown inFIG.10, the cover assembly may include an anchor plate cover210, inner cover215, and outer cover220having a chrome finish. Various embodiments of the cover assembly may have any other desired aesthetic finish known in the art. Accordingly, when the hinge100is implemented to couple the panel10to a structure, the slider piece140may be inserted into (e.g., via press-fit, snap-fit, etc.) the cutout182of the panel10. As noted previously, when the slider piece140is inserted into the panel10, the slider piece140remains stationary relative to the panel10. The inner plate130and the outer plate125may be coupled together through the panel10via the support fasteners135, which may engage with the boss feature172on the outer plate125, and pass through the slot165within the slider piece140. The outer plate125may be coupled to the anchor plate105(via the arm115) and the anchor plate105may be coupled to a structure prior to coupling the inner plate130to the outer plate125. The indicator tab170, which is disposed within and laterally articulates relative to the slot150as the panel10moves (i.e., when the hinge100articulates), indicates lateral movement of the panel10within the slot165and, thus, indicates an adjustment position of the panel10relative to the hinge100. As the inner plate130and the outer plate125are mutually coupled, the receiving portion120of the outer plate125may be positioned within and engage with the recess185of the panel10. The anchor plate105may also be coupled to the structure via the fasteners110. Finally, to adjust for potential out-of-plumb conditions of the panel10and the structure, the indicator tab170of the slider piece140may be used to indicate movement of the panel10relative to the boss feature172and thus indicate adjustment of the panel10relative to the hinge100. When the panel10and the hinge100have been suitably adjusted to correct for fit and/or out-of-plumb conditions, the support fasteners135may be tightened such that the inner plate130and the outer plate125exert a force on the panel10to hold the panel10in the adjusted position. Should repositioning of the panel10become necessary, the support fasteners135may be loosened and the panel10may be repositioned relative to the hinge100by sliding the panel10relative to the boss feature172. Accordingly, the hinge100may be installed within a structure and loosely coupled to the panel10. Correction of out-of-plumb conditions may then be addressed by articulating the hinge100, allowing the panel10(via the slider piece140) to slide relative to the hinge100components thereby correcting out-of-plumb conditions, and adjusting (i.e., tightening) the support fasteners135to maintain the panel10in the corrected position. Notwithstanding the embodiments described above and shown inFIGS.1-10, various modifications and inclusions to those embodiments are contemplated and considered within the scope of the present disclosure. As utilized herein with respect to numerical ranges, the terms “approximately,” “about,” “substantially,” and similar terms generally mean +/−10% of the disclosed values, unless specified otherwise. As utilized herein with respect to structural features (e.g., to describe shape, size, orientation, direction, relative position, etc.), the terms “approximately,” “about,” “substantially,” and similar terms are meant to cover minor variations in structure that may result from, for example, the manufacturing or assembly process and are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the disclosure as recited in the appended claims. It should be noted that the term “exemplary” and variations thereof, as used herein to describe various embodiments, are intended to indicate that such embodiments are possible examples, representations, or illustrations of possible embodiments (and such terms are not intended to connote that such embodiments are necessarily extraordinary or superlative examples). The term “coupled” and variations thereof, as used herein, means the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent or fixed) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members coupled directly to each other, with the two members coupled to each other using a separate intervening member and any additional intermediate members coupled with one another, or with the two members coupled to each other using an intervening member that is integrally formed as a single unitary body with one of the two members. If “coupled” or variations thereof are modified by an additional term (e.g., directly coupled), the generic definition of “coupled” provided above is modified by the plain language meaning of the additional term (e.g., “directly coupled” means the joining of two members without any separate intervening member), resulting in a narrower definition than the generic definition of “coupled” provided above. Such coupling may be mechanical, electrical, or fluidic. References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below”) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure. Although the figures and description may illustrate a specific order of method steps, the order of such steps may differ from what is depicted and described, unless specified differently above. Also, two or more steps may be performed concurrently or with partial concurrence, unless specified differently above. It is important to note that any element disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein. For example, the cover assembly of the exemplary embodiment described in at least paragraph [0050] may be incorporated in the hinge100of the exemplary embodiment described in at least paragraph [0037]. Although only one example of an element from one embodiment that can be incorporated or utilized in another embodiment has been described above, it should be appreciated that other elements of the various embodiments may be incorporated or utilized with any of the other embodiments disclosed herein. | 33,731 |
11859427 | DETAILED DESCRIPTION Hinges1have two hinge elements2,3which are articulated so as to be mutually pivotable and which enable a closing element such as, for example, a door leaf, a porthole window, window leaf, a cover, or a hatch, to be pivoted in relation to a frame. To this end, a hinge element2is disposed on the closing element, and a hinge element3is disposed on the frame. An opening which is surrounded by the frame and which can be, for example, a door, a porthole, or a window, herein can be closed or released in a simple manner. In order for uniform closing of the opening by the closing element to be enabled and also for a sealing element, such as a sealing lip or a sealing bead, which is disposed between the frame and the closing element to be compressed herein for sealing, the hinge1has to be aligned. The hinge1according to the invention enables a simple and precise alignment. Two potential exemplary embodiments of said hinge1are to be discussed in more detail hereunder by means of the figures. According to the invention, the frame does not have to be a separate element. The frame can also be formed by the edge of a wall or similar that surrounds the opening. FIG.1andFIG.2herein show different perspective views of a first exemplary embodiment of the hinge1. The hinge element2, by way of connecting means on the lower side (not illustrated) of said hinge2, can be disposed on a closing element. The hinge element3is disposed on the frame (not illustrated) of the opening. Nevertheless, it is also possible for either of the two, or both, hinge elements2,3to also be partially or entirely disposed within the closing element or the frame, respectively. The hinge element2can likewise be disposed on the frame, and the hinge element3can likewise be disposed on or in the closing element. The box-shaped hinge element2and the elongate hinge element3are preferably composed of injection-molded plastics material but may also comprise metallic elements, in particular in the region of the hinge axis A, or be completely composed of metal. The illustrated hinge1is configured in the manner of a closure hinge. Said hinge1has an activating device6which is disposed on the hinge element2, the function of said activating device6yet to be described in more detail. The two hinge elements2,3are connected to one another by way of a hinge axis A in an articulated manner such that said two hinge elements2,3can be mutually pivoted. The hinge axis A runs so as to be substantially parallel to the plane of the closing element (not illustrated). In order for the spacing of the hinge axis A in relation to the hinge element3to be adjusted, the illustrated hinge1has two actuating elements5, wherein a single actuating element5would however also be sufficient for adjusting the space of the hinge axis A according to the invention. The actuating elements5for visualization are illustrated so as to be spaced apart in relation to the hinge elements2,3inFIG.1andFIG.2. In the assembled state of the hinge1, the actuating elements5are however plug-fitted in bearing openings4.1of an axle support4which is disposed between the two hinge elements2,3. Said axle support4supports the hinge axis A. By varying the spacing of the axle support4in relation to the hinge element3, the spacing of the hinge axis A in relation to the hinge element3herein is simultaneously adjusted in a simple manner in terms of construction. As can be seen inFIG.1, the cylindrical actuating element5has a thread5.1which serves for connecting the actuating element5to the hinge element3. The actuating element5on the side which is diametrically opposite the thread5.1has a head5.3which forms the termination of the actuating element5. The head5.3has a radius which is larger than that of the thread5.1but may also be configured so as to have a radius which is identical to that of the thread5.1. Moreover, the head5.3comprises a drive region5.4which is configured in the manner of a hexagonal socket. Alternatively, the drive region5.4can be configured in the form of a hexagonal pilot, a hexalobular socket, a slot, or a cross head. The actuating element5by way of said drive region5.4is coupled to a drive apparatus (not illustrated) such as a screw driver or an electric screwdriver, for example, for driving the actuating movement. The actuating element5overall has a substantially screw-like geometry. In order to be disposed on the axle support4, the actuating element5by way of a groove5.2has a circumferential constriction. The groove5.2is delimited by the thread5.1and the head5.3but may nevertheless also be spaced apart from said thread5.1and said head5.3. The groove5.2enables a rotatable yet axially fixed disposal on the axle support4. To this end, the groove5.2is configured in the manner of a variation of the radius which is abruptly sent back toward the inside. This enables the groove5.2to be mounted in a form-fitting manner in the bearing opening4.1. Shear and traction forces for setting the spacing in relation to the hinge element3herein can be transmitted from the actuating element5to the axle support4. The hinge element3illustrated inFIG.1will be explained in more detail hereunder by means of the illustration inFIG.3. Said hinge element3has a bar-shaped geometry having a height which is substantially less than the length. Two protrusions3.02protrude from the side3.01that faces the axle support4. Said protrusions3.02support in each case one mating thread3.1which for connecting the actuating element5interacts with the thread5.1of the latter. The mating thread3.1is configured as an internal thread of a threaded bore. Apart from the protrusions3.02, the hinge element3has in each case one countersink3.5in which a connection recess3.2is located. Said connection recess3.2herein serves for disposing the hinge element3on the frame, wherein a connecting means (not illustrated) such as, for example, a screw or a rivet, is guided through the connection recess3.2. The hinge element3can in this way be connected directly to the frame, or can be connected to one or a plurality of further elements for disposal on the frame. The countersink3.5ensures that the connecting means does not protrude from the side3.01of the hinge element3and does not impede the actuating movement of the axle support4. A recess3.3which is disposed between the mating threads3.1in the assembled state of the hinge1permits a free rotating movement of the hinge element2which is disposed about the hinge axis A. Any collision of the regions of the hinge element2that are disposed about the hinge axis A of the axle support4and the hinge element3is avoided on account of the recess3.3. The hinge element2is provided with sufficient freedom of movement even at a minor spacing of the hinge axis A from the hinge element3. The hinge element3moreover has a guide region3.4for guiding the actuating movement of the axle support4. Said guide region3.4interacts with a guide region4.4of the axle support4illustrated inFIG.4. Both guide regions3.4,4.4conjointly form a guide for guiding the actuating movement of the axle support4. To this end, said guide regions3.4,4.4by way of the contact faces3.41,4.41bear on one another in the manner of a sliding guide. The guide region3.4divided into two parts is configured so as to be complementary to the guide region4.4and receives the latter, this enabling the movement of the axle support4to be guided in a form-fitting manner. Hinge forces which act transversely to the actuating element5, that is to say substantially parallel to the side3.01, are transmitted from the axle support4to the hinge element3by the guide3.4,4.4. An impingement of the actuating element5with said hinge forces, which is disadvantageous in terms of connection technology, is prevented. The actuating elements5to this extent lie outside the flux of force. The hinge element3and the axle support4, by way of the guide3.4,4.4, are configured in the manner of interacting plug-fit connection elements. The axle support4by way of the guide region4.4herein partially encompasses the hinge element3along the section plane illustrated inFIG.5. In contrast, the guide region3.4along the longitudinal direction of the hinge element3, that is to say transversely to the section plane ofFIG.5, surrounds the guide region4.4of the axle support4and thus receives said guide region4.4. The axle support4according toFIG.1is illustrated in more detail inFIG.4. The spacing of the axle support4from the hinge element3, conjointly with the spacing of the hinge axis A, can be set by way of the actuating element5. The dumbbell-shaped axle support4has a cylindrical joint pin4.3which, for disposing the hinge element2in an articulated manner, is disposed so as to be coaxial with the hinge axis A. Moreover, the axle support4has two connection elements4.5which are mutually opposite along the hinge axis A. Said connection elements4.5likewise serve for connecting to the hinge element2and engage in receptacles2.5of the hinge element that are illustrated inFIG.7. Passages4.2render the connecting means accessible from the outside in order for the hinge element3to be connected by way of the connection recesses3.2, without the axle support4having to be removed to this end. For this purpose, the passages4.2are disposed on the axle support4in such a manner that said passages4.2in the assembled state of the hinge1are aligned with the connection recesses3.2. The bearing openings4.1are disposed on both sides of the joint pin4.3, a disposal of the actuating elements5on both sides being achieved on account thereof. The two actuating elements5, apart from adjusting the spacing of the hinge axis A in relation to the hinge element3, also enable the hinge axis A to be inclined. A distortion of the closing element and/or of the frame due to production tolerances or use can be equalized by the adjustable oblique positioning of the hinge axis A. Dissimilar spacings between the hinge axis A and the hinge element3are adjusted herein by means of the actuating elements5, on account of which an inclination of the hinge axis A in relation to the hinge element3results. As described above, the actuating element5is mounted in a bearing opening4.1of the axle support4. The bearing opening4.1has a bearing region4.11and a plug-fit region4.12. The plug-fit region4.12is dimensioned so as to be larger in comparison to the bearing region4.11. This enables the actuating element5to be plug-fitted in the plug-fit region4.12with the thread5.1and/or the head5.3leading. To this end, the internal radius of the plug-fit region4.12is at least the size of the external diameter of the thread5.1and/or of the head5.3of the actuating element5. In contrast, the bearing region4.11has an internal diameter which is less than the external diameter of the thread5.1and/or of the head5.3of the actuating element5. On account of said smaller internal diameter of the bearing region4.11it is prevented that an actuating element5that is mounted in the bearing region4.11can depart from the bearing region4.11in the axial direction. An axial restriction of the freedom of movement of the actuating element5is achieved. The radius of the bearing region4.11corresponds substantially to the external diameter of the groove5.2of the actuating element5. The axial dimension of the bearing region4.11likewise corresponds substantially to the axial length of the groove5.2. The groove5.2can in this way be mounted in a form-fitting manner in the bearing region4.11. The shear and traction forces for adjusting the spacing from the hinge element3are thus transferred from the actuating element5to the axle support4. The bearing region4.11and the plug-fit region4.12form a keyhole-shaped bearing opening4.1in which the two substantially circular regions4.11and4.12are connected to one another by way of an elongate bore which runs between the two regions4.11,4.12. The smaller diameter of said elongate bore herein corresponds substantially to the internal diameter of the bearing region4.11. In order for the head5.3of the actuating element5to be received, the bearing opening4.1is disposed in a countersink4.6. This enables the actuating element5to be mounted in the bearing opening4.1and prevents the head5.3from projecting from the upper side of the axle support4. The bearing opening4.1and the guide region4.4are mutually disposed in such a manner that the actuating element5, which in the case of the assembled hinge1in which the guide region4.4bears on the guide region3.4is established by way of the mating thread3.1, cannot be transferred from the bearing region4.11to the plug-fit region4.12. Any unintentional departure of the actuating element5from the bearing opening4.1, and thus a release of the axle support4from the actuating element5, is prevented in the assembled state. When assembling the hinge1, the actuating element5is first plug-fitted in the plug-fit region4.12of the axle support4and, in order for the groove5.2to engage in the bearing region4.11, is displaced transversely to the plug-fitting direction. The actuating element5mounted in the axle support4is subsequently connected to the hinge element3by means of the thread5.1and the mating thread3.1. Alternatively, an engagement between the thread5.1and the mating thread3.1is first established, and the axle support4is subsequently plug-fitted on the actuating element5in such a manner that the actuating element5is plug-fitted in the plug-fit region4.12. Thereafter, the axle support4is displaced in relation to the actuating element5and the hinge element3in order for the actuating element5to be transferred to the bearing region4.11. The second alternative requires that the axle support4by way of the actuating element5can be spaced apart from the hinge element3in such a manner that the guide regions3.4,4.4no longer bear on one another. FIG.5andFIG.6show sectional views of the hinge1according toFIG.1for dissimilarly adjusted spacings of the hinge axis A from the hinge element3. There is a smaller spacing D1between the hinge element3and the axle support4inFIG.5. The guide regions3.4and4.4bear on one another. The protrusion3.02herein forms part of the guide region4.4and in terms of length extends the latter along the axial direction of the actuating element5. Hinge forces which act transversely to the axis of the actuating element5can be transferred from the axle support4to the hinge element3without having any effect on the actuating element5. In order for the spacing D1to be varied and thus also for the spacing of the hinge axis A disposed on the axle support4from the hinge element3to be adjusted, the adjustment element5is rotated about the longitudinal axis thereof. On account of the interaction between the thread5.1and the mating thread3.1, this rotating movement is converted to an axial longitudinal movement of the actuating element5. A shear or traction force exerted on account of the axial longitudinal movement is transferred to the axle support4by way of the axial fixing of the actuating element5described above. The axle support4by way of the shear or traction force is moved away from the hinge element3or toward the latter and herein is guided by the guide3.4,4.4. The maximum achievable spacing D2which still permits a guided movement is shown inFIG.6. The contact faces3.41and4.41of the guide regions3.4,4.4in the region of the section illustrated on the left still bear on one another, while the parts of the guide regions3.4,4.4illustrated on the right already no longer bear on one another. FIG.7shows a perspective view of the closing-element-proximal hinge element2. The slot-shaped receptacles2.5in which the connection elements4.5engage in order to connect the axle support4to the hinge element2can be seen. A link eye2.1as part of a rod-shaped protrusion2.6lies along the hinge axis A between said receptacles2.5. Said link eye2.1is disposed on the joint pin4.3of the axle support4and enables the articulated connection of the two hinge elements2,3by means of the axle support4. To this end, the joint pin4.3bears on the internal face of the link eye2.1, this enabling articulated guiding of the pivoting movement of the hinge element2in relation to the axle support4. The link eye2.1is configured in the manner of a passage opening through the protrusion2.6, said passage opening been open on one side of the circumference. In order to be disposed on the joint pin4.3, the link eye2.1in the direction of the region that is open on one side can be moved toward the joint pin4.3. Alternatively, the link eye2.1can also be configured as a circumferentially closed passage opening, on account of which a circumferential form-fit between the joint pin4.3and the link eye2.1can be achieved. A link eye2.1which is open on one side permits the link eye2.1to be released and locked in a simple manner on the joint pin4.3. To this end, the hinge element2has a locking mechanism2.3which can be seen inFIG.8, for example. Said locking mechanism2.3for locking the link eye2.1to the joint pin4.3is moved out of a recess2.2in a manner parallel to the protrusion2.6, and for releasing said link eye2.1from the joint pin4.3is moved into the recess2.2in a manner parallel to the protrusion2.6. The locking mechanism2.3in the locked state locks the link eye2.1that is open on one side in such a manner that the link eye2.1and the locking mechanism2.3bear in a form-fitting manner on the joint pin4.3. The locking mechanism2.3in the unlocked state is moved into the recess2.2in such a manner that said locking mechanism2.3releases the joint pin4.3bearing on the link eye2.1. The locking mechanism2.3in the unlocked state is preferably completely retracted into the recess2.2. The activating device6which is configured in the manner of a handle and is disposed in the recess2.4of the hinge element2serves for activating the locking mechanism2.3. The hinge1equipped with a locking mechanism2.3, apart from the function as a hinge, can at the same time also be used in the manner of a closure hinge for closing and/or locking. The hinge1can thus be used as a replacement for or as an addition to a lock. If a plurality of said hinges1are used at various locations of the closing element of a closable opening, said hinges1can enable the opening direction of the closing element to be selected. The link eye2.1of the hinge1about which the closing element is to be pivoted, herein can remain in a position locked to the joint pin4.3, while the link eyes2.1of the remaining hinges1by moving the respective locking mechanism2.3are released from the joint pins4.3assigned to said link eyes2.1. The closing element in this instance can be pivoted about the hinge1which is still locked. In order for the closing element to be locked in the closed position thereof, the respective joint pins4.3and link eyes2.1of the hinges1are locked to one another. Particularly stable locking of the closing element can be achieved in this way. A further exemplary embodiment of a hinge1according to the invention is to be discussed hereunder. Elements with equivalent functions herein are identified by the same reference signs as have already been used in the description of the first exemplary embodiment. The substantial difference in comparison to the first exemplary embodiment lies in design details of the hinge element3and of the axle support4. Only the points of differentiation in relation to the first exemplary embodiment will therefore be discussed hereunder, wherein the description above to this extent also applies to the second exemplary embodiment. FIG.8shows the hinge1having the two hinge elements2,3, the axle support4, and the activating device6. The activating device6and the hinge element2differ from the first exemplary embodiment only in terms of the shape of their contours, while their technical functionality is not affected thereby. The axle support4is configured so as to be more square-edged and has lines which do not flow as much in comparison to the first exemplary embodiment, on account of which a smaller width transverse to the hinge axis A is achieved in a space-saving manner. The hinge element3inFIG.8is illustrated separately from the axle support4. This is for the sake of clarity since the axle support4in the assembled state of the hinge1obscures the hinge element3. FIG.9shows a sectional illustration of the hinge at a spacing of the hinge axis A from the hinge element3that is adjusted to the minimum. The actuating movement of the axle support4on both sides in the direction of the section as well as transverse to the latter is guided by the two guide regions3.4,4.4which bear on one another. The guide region4.4of the axle support4encompasses the guide region3.4of the hinge element3on both sides. For guiding the actuating movement, the inward-facing contact face4.41of the axle support4herein bears on the outward-facing contact face3.41of the hinge element3. As can be seen inFIG.10, apart from extending along the long sides of the axle support4or of the hinge element3, respectively, the guide regions3.4and4.4also extend along the respective short sides. The internal circumferential face of the axle support4and the external circumferential face of the hinge element3in a manner which is simple in terms of construction form the contact faces3.41,4.41which bear on one another in order for the actuating movement to be guided. The axle support4and the hinge element3are shaped so as to be mutually complementary in the manner of a plug-fit connection in which the axle support4circumferentially surrounds the plank-shaped hinge element3. In order for the actuating elements5to be mounted, the axle support4again has keyhole-shaped bearing openings4.1which are disposed in countersinks4.6. The two bearing openings4.1are mutually aligned in such a manner that the bearing regions4.11of the two bearing openings4.1face one another. An additional safeguard against the actuating elements5departing from the bearing openings4.1is achieved on account thereof. Since the grooves5.2prevent any departure of the actuating elements5from the bearing regions4.11in the axial direction, the actuating elements5would have to be transferred to the larger plug-fit regions4.12in order to be able to depart from the latter. However, by virtue of the disposal of the bearing regions4.11so as to align with the mating threads3.1, an actuating element5that is connected to the mating thread3.1cannot be freely transferred to the plug-fit region4.12. The mutually facing bearing regions4.11of the bearing openings4.1moreover prevent that the axle support4in relation to the actuating elements5which are established relative to the hinge element3is displaced in such a manner that the actuating elements5enter the plug-fit regions4.12. This is because the axle support4to this end would have to be moved along the hinge axis A in another direction for each of the two actuating elements5. Such a movement which corresponds to a compression of the axle support4is not possible in the case of the fixed axle support4. Therefore, the actuating elements5cannot depart from the bearing opening4.1without being released from the hinge element3. An alignment which is simpler and more precise can be achieved by using the hinge1described above and the method for adjusting the hinge1. LIST OF REFERENCE SIGNS 1Hinge2Hinge element2.1Link eye2.2Recess2.3Locking mechanism2.4Recess2.5Receptacle2.6Protrusion3Hinge element3.01Side3.02Protrusion3.1Mating thread3.2Connection recess3.3Recess3.4Guide region3.41Contact face3.5Countersink4Axle support4.1Bearing opening4.11Bearing region4.12Plug-fit region4.2Passage4.3Joint pin4.4Guide region4.41Contact face4.5Connection element4.6Countersink5Actuating element5.1Thread5.2Groove5.3Head5.4Drive region6Activating deviceA Hinge axisD1SpacingD2Spacing | 23,902 |
11859428 | DETAILED DESCRIPTION OF THE INVENTION 100—Automatic door device;101—Top cover;102—Bottom cover;103—First through hole;101—Driving motor;110a—Output shaft of the driving motor;111—Worm;112—Turbine;113—First shaft;114—First accommodating portion;115—Magnet;120—Transmission system;120a—input end of the transmission system;121—First set of transmission gears;122—Second set of transmission gears;120b—Output end of the transmission system;130—Clutch mechanism;130a—input end of the clutch mechanism;130b—Output end of the clutch mechanism;131—First main gear;132—First auxiliary gear;133—Limiting portion;134—Adaptation portion;135—Fifth shaft;136—Fifth accommodating portion;137—Limiting groove;138—Boss;137a—First closed end;137b—Second closed end;141—Third main gear;142—Third auxiliary gear;143—Second shaft;144—Second accommodating portion;150—Torque control mechanism;151—Second main gear;152—Second auxiliary gear;153—Third shaft;154—Third accommodating portion;155—First transmission gear;156—Fourth shaft;157—Fourth accommodating portion;158—Second transmission gear;159—Second through hole;159a—Notch of the second through hole;160—Elastic piece;161—Protruding portion;170—Control module;171—First fixing portion;180—Angle sensing module;181—Third transmission gear;182—Angle sensor;183—Sixth accommodating portion;184—Third through hole;190—Speed monitoring module;191—Second fixing portion;200—Household appliance;201—Body;202—Door body;203—Door shaft;204—Door end cover;205—Shaft hole; and α—Rotation angle of the door body. DETAILED DESCRIPTION As described in the Background, the existing household appliances are generally not equipped with the automatic door system, or although are equipped with the automatic door system, the requirement of the user for operation convenience cannot be met while the automatic door function is implemented, affecting the user experience. To resolve the foregoing technical problem, an embodiment of the present invention provides an automatic door device, including a driving motor and a transmission system. An input end of the transmission system is coupled to an output shaft of the driving motor, an output end of the transmission system is coupled to a door shaft, and the transmission system includes a transmission link to transmit an output torque of the driving motor to the door shaft. A clutch mechanism is disposed on the transmission link of the transmission system. According to the solution in this embodiment, when the door is subjected to an external force, the transmission link between the door and the driving motor can be automatically disconnected by using the clutch mechanism, so that while an automatic door function is implemented, it is ensured that a user may not be affected by the resistance brought by the automatic door device when the user opens/closes the door manually, thereby optimizing user experience. To make the foregoing objectives, features and advantages of the present invention more obvious and understandable, specific embodiments of the present invention are described in detail with reference to the accompanying drawings. FIG.1is a schematic diagram of an automatic door device according to an embodiment of the present invention; andFIG.2is an exploded view of the automatic door device shown inFIG.1. To show the internal structure of an automatic door device100more clearly, a top cover101inFIG.2is not shown inFIG.1. Specifically, referring toFIG.1andFIG.2, the automatic door device100in this embodiment may include a driving motor110and a transmission system120. An input end120aof the transmission system120may be coupled to an output shaft110aof the driving motor110, an output end120bof the transmission system120may be coupled to a door shaft203(as shown inFIG.15), and the transmission system120may have a transmission link to transmit an output torque of the driving motor110to the door shaft203. A clutch mechanism130is disposed on the transmission link of the transmission system120. According to the solution in this embodiment, when a door body202(as shown inFIG.15) is subjected to an external force, the automatic door device100may automatically disconnect the transmission link between the door and the driving motor110by using a clutch mechanism130, so that while an automatic door function is implemented, it is ensured that a user may not be affected by the resistance brought by the automatic door device100when the user opens/closes the door manually, thereby optimizing user experience. For example, the automatic door device100may include a top cover101and a bottom cover102. Components such as the driving motor110, the transmission system120, and the clutch mechanism130are all disposed on one side of the bottom cover102facing the top cover101, and the top cover101is adapted to cover the bottom cover102, to seal the foregoing components into a cavity formed by the top cover101and the bottom cover102. Further, first through holes103are respectively provided at suitable locations at the top cover101and the bottom cover102, and the first through holes103are adapted for the door shaft203to pass through. Therefore, the door shaft203passes through the automatic door device100and hinges the door body202and the body201of the household appliance200(as shown inFIG.15), and the door shaft203may be driven by the driving motor110to implement the automatic door function. Further, the clutch mechanism130may be in an engaged state when the door shaft203is not subjected to an external torque; and the clutch mechanism130may enter a separated state to disconnect the transmission link when the door shaft203is subjected to an external torque in a same direction. Based on this, in the engaged state, an output torque of the driving motor110may be transmitted to the door shaft203by using the transmission link, to implement an automatic door effect by using the driving motor110to drive the door shaft203to rotate; and in the separated state, the transmission link is disconnected, the output torque of the driving motor110cannot be transmitted to the door shaft203, and the door shaft203is not subjected to the force applied by the driving motor110, so that the user can operate the door body202casually without feeling additional resistance. Further, the same direction refers to being in the same direction with the torque applied by the transmission system120to the door shaft203. For example, when the transmission system120is driven by the driving motor110to drive the door shaft203to rotate to open the door, the user manually operates the door body202to accelerate the opening of the door, and in this case, the clutch mechanism130enters a separated state, to ensure that the user can softly open the door manually. For another example, during the transmission system120is driven by the driving motor110to drive the door shaft203to rotate to close the door, the user manually operates the door body202to accelerate the closing of the door, and in this case, the clutch mechanism130enters a separated state, to ensure that the user can softly close the door manually. In an embodiment, with reference toFIG.1toFIG.3, the transmission system120may include: a first set of transmission gears121, where a first gear in the first set of transmission gears121is coupled to the output shaft110aof the driving motor110, and a last gear is coupled to the input end130aof the clutch mechanism130; and a second set of transmission gears122, where a first gear in the second set of transmission gears122is coupled to the output end130bof the clutch mechanism130, and a last gear is coupled to the door shaft203. Based on this, when the clutch mechanism130is in an engaged state, the first set of transmission gears121and the second set of transmission gears122are coupled through the clutch mechanism130, to make the transmission link connected; and when the clutch mechanism130is in a separated state, the first set of transmission gears121and the second set of transmission gears122are separated from each other under the action of the clutch mechanism130, to make the transmission link disconnected. For example, the output shaft110aof the driving motor110is coupled to a worm111, the worm111is coupled to a turbine112, and the turbine112is coupled to the first gear of the first set of transmission gears121. Specifically, the turbine112is rotatably fixed on the bottom cover102through a first shaft113, a first accommodating portion114may be fixed on the bottom cover102, and the first shaft113may be inserted into an accommodating hole provided on the first accommodating portion114to fix the turbine112. Further, the first set of transmission gears121may include a third main gear141and a third auxiliary gear142that are disposed coaxially, and the two gears may be rotatably fixed on the bottom cover102through a second shaft143. In addition, the third main gear141and the third auxiliary gear142may rotate synchronously around the second shaft143. The third main gear141may be the first gear of the first set of transmission gears121. That is, the third main gear141is coupled to the turbine112. Further, a second accommodating portion144may be fixed on the bottom cover102, and the second shaft143may be inserted into an accommodating hole provided on the second accommodating portion144, to fix the third main gear141and the third auxiliary gear142. Further, the first set of transmission gears121may further include a second main gear151and a second auxiliary gear152that are disposed coaxially, and the two gears may be rotatably fixed on the bottom cover102through a third shaft153. In addition, the second main gear151and the second auxiliary gear152may rotate synchronously around the third shaft153. Further, a third accommodating portion154may be fixed on the bottom cover102, and the third shaft153may be inserted into an accommodating hole provided on the third accommodating portion154, to fix the second main gear151and the second auxiliary gear152. Further, the third auxiliary gear142is engaged with and the second main gear151, and the second auxiliary gear152is coupled to the input end130aof the clutch mechanism130. Therefore, the output torque of the driving motor110is transmitted to the third main gear141through the worm111and the turbine112sequentially by the output shaft110aof the driving motor110. Then, the output torque is transmitted to the second main gear151engaged with the third auxiliary gear by the third auxiliary gear142rotating synchronously with the third main gear141, and is then transmitted to the input end130aof the clutch mechanism130coupled to the second auxiliary gear152by the second auxiliary gear152rotating synchronously with the second main gear151. For another example, the second set of transmission gears122may include a first transmission gear155coupled to the output end130bof the clutch mechanism130. Specifically, the first transmission gear155may be rotatably fixed on the bottom cover102through a fourth shaft156. Further, a fourth accommodating portion157may be fixed on the bottom cover102, and the fourth shaft156may be inserted into an accommodating hole provided on the fourth accommodating portion157, to fix the first transmission gear155. Further, the second set of transmission gears122may further include a second transmission gear158. The second transmission gear158is engaged with the first transmission gear155, and a second through hole159for the door shaft203to pass through is provided on the second transmission gear158axially. Further, the second through hole159may have a notch159a, so that the door shaft203passing through and the second transmission gear122may not move relatively. That is, the first transmission gear155may be the first gear of the second set of transmission gears122, and the second transmission gear158may be the last gear of the second set of transmission gears122. Such a design is beneficial to save space occupied by the automatic door device100. Therefore, when the clutch mechanism130is in an engaged state, after the output torque of the driving motor110is transmitted to the input end130aof the clutch mechanism130through the first set of transmission gears121, the output torque is further transmitted to the output end130bof the clutch mechanism130. Then, the output torque is transmitted to the second transmission gear158engaged with the first transmission gear155through the coupled first transmission gear155, and the door shaft203is driven to rotate synchronously through the rotation of the second transmission gear158. Therefore, based on the torque transmission of the transmission link, the output torque of the driving motor110can be effectively transmitted to the door shaft203, to implement the automatic door function for the door body202. In actual application, the quantity of the gears or gear pairs included in the first set of transmission gears121may be one or more. That is, the first gear and the last gear of the first set of transmission gears121may be the same one. Similarly, the quantity of the gears or gear pairs included by the second set of transmission gears122may be one or more. That is, the first gear and the last gear of the second set of transmission gears122may be the same one. In an embodiment, with reference toFIG.1toFIG.6, the clutch mechanism130may include: a first main gear131, coupled to the last gear in the first set of transmission gears121; and a first auxiliary gear132, disposed coaxially with the first main gear131, and coupled to the first gear in the second set of transmission gears122. A limiting portion133is disposed at one side of the first main gear131facing the first auxiliary gear132, and an adaptation portion134is disposed at one side of the first auxiliary gear132facing the first main gear131. When the first main gear131is driven by the first set of transmission gears121to rotate to the limiting portion133to abut against the adaptation portion134, the clutch mechanism130is in an engaged state; and when the first auxiliary gear132is driven by the second set of transmission gears122to rotate to the adaptation portion134to be separated from the limiting portion133, the clutch mechanism130is in a separated state. Therefore, through the cooperation between the limiting portion133and the adaptation portion134, the clutch mechanism130can freely switch between the engaged state and the separated state, to implement connection and disconnection of the transmission link. For example, the first main gear131is engaged with the second auxiliary gear152, and the first auxiliary gear132is engaged with the first transmission gear155. Further, the first main gear131and the second main gear132may be rotatably fixed on the bottom cover102through a fifth shaft135. Correspondingly, a fifth accommodating portion136is fixed on the bottom cover102, and the fifth shaft136may be inserted into an accommodating hole provided on the fifth accommodating portion136, to fix the first main gear131and the second main gear132. In an embodiment, referring toFIG.2andFIG.5, the limiting portion133may include a limiting groove137, and the limiting groove137may have a first closed end137aand a second closed end137b. Further, the clutch mechanism130is in an engaged state when the limiting groove137rotates with the first main gear131to the adaptation portion134to abut against the first closed end137aor the second closed end137b. Further, the clutch mechanism130is in a separated state when the adaptation portion134rotates with the first auxiliary gear132to be separated from the first closed end137aor the second closed end137band slides in the limiting groove137. Therefore, when the limiting groove137rotates with the first main gear131to the adaptation portion134to abut against the first closed end137aor the second closed end137b, the clutch mechanism130is in an engaged state and the door shaft203can rotate along the opening direction or the closing direction under the drive of the driving motor110; and when the door shaft203is subjected to an external torque in the same direction, the design of the limiting groove137provides a free motion distance for the adaptation portion134, so that the door shaft203can accelerate the rotation without being limited by the resistance of the driving motor110. Further, referring toFIG.6, the adaptation portion134may include a boss138, to be effectively coupled to the limiting groove137, to ensure that the clutch mechanism130can flexibly switch between the engaged state and the separated state. Further, the engaged state of the clutch mechanism130may include a first engaged state and a second engaged state. When the boss138abuts against the first closed end137aof the limiting groove137, the clutch mechanism130is in the first engaged state; and when the boss138abuts against the second closed end137bof the limiting groove137, the clutch mechanism130is in the second engaged state. It is assumed that when the first main gear131and the first auxiliary gear132rotate along a clockwise direction, the direction is an opening direction. When the clutch mechanism130is in the first engaged state, the output torque of the driving motor110is transmitted to the door shaft203through the transmission link, and the door body202can be controlled to open automatically; and when the clutch mechanism130is in the second engaged state, the output torque of the driving motor110is transmitted to the door shaft203through the transmission link, and the door body202can be controlled to close automatically. In a typical application scenario, referring toFIG.7, the boss138abuts against the first closed end137aof the limiting groove137, and the output torque of the driving motor110is transmitted to the first main gear131through the first set of transmission gears121, so that the first main gear131rotates along the clockwise direction. In this case, because the boss138abuts against the first closed end137aof the limiting groove137, the first auxiliary gear132rotates clockwise synchronously under the drive of the first main gear131, to further drive the first transmission gear155engaged with the first auxiliary gear132to rotate, and the rotation of the first transmission gear155further drives the second transmission gear158engaged with the first transmission gear155to rotate. Therefore, the clutch mechanism130in the first engaged state transmits the output torque of the driving motor110to the door shaft203, to implement automatic door opening. In another typical application scenario, referring toFIG.8, the boss138abuts against the second closed end137bof the limiting groove137, and the output torque of the driving motor110is transmitted to the first main gear131through the first set of transmission gears121, so that the first main gear131rotates along an anticlockwise direction. In this case, because the boss138abuts against the second closed end137bof the limiting groove137, the first auxiliary gear132rotates anticlockwise synchronously under the drive of the first main gear131, to further drive the first transmission gear155engaged with the first auxiliary gear132to rotate, and the rotation of the first transmission gear155further drives the second transmission gear158engaged with the first transmission gear155to rotate. Therefore, the clutch mechanism130in the second engaged state transmits the output torque of the driving motor110to the door shaft203, to implement automatic door closing. In still another typical application scenario, with reference toFIG.7andFIG.9, when the first auxiliary gear132rotates with the first main gear131synchronously along the clockwise direction, if the door shaft203is subjected to an external torque in the same direction with the current rotation direction. Under the action of the external torque in the same direction, the door shaft203may in turn drive the second transmission gear158to rotate faster along the current rotation direction. Further, the second transmission gear158drives the first transmission gear155engaged with the second transmission gear158to rotate faster along the current rotation direction, and the first transmission gear155drives the first auxiliary gear132engaged with the first transmission gear155to rotate faster along the clockwise direction. In this case, under the action of the external torque in the same direction, the rotation speed of the first auxiliary gear132along the clockwise direction is greater than the rotation speed of the first main gear131along the clockwise direction. The rotation speed of the first main gear131along the clockwise direction is determined by the output torque of the driving motor110transmitted through the first set of transmission gears121. Because the first auxiliary gear132moves relatively relative to the first main gear131along the clockwise direction, as shown inFIG.9, the boss138leaves the first closed end137aof the limiting groove137, and slides along the limiting groove137. During the sliding, the clutch mechanism130enters the separated state, the output torque of the driving motor110cannot be transmitted to the door shaft203due to the disconnection of the transmission link. Therefore, the door shaft203may move casually under the action of the external torque without being affected by the output torque of the driving motor110. Therefore, in the scenarios shown inFIG.7andFIG.9, accelerating the opening of the door may be implemented by manual operation of the user on a basis of automatic opening of the door at a constant speed. In another typical application scenario, with reference toFIG.8andFIG.9, when the first auxiliary gear132rotates with the first main gear131synchronously along the anticlockwise direction, if the door shaft203is subjected to an external torque in the same direction with the current rotation direction, under the action of the external torque in the same direction, the door shaft203may in turn drive the second transmission gear158to rotate faster along the current rotation direction. Further, the second transmission gear158drives the first transmission gear155engaged with the second transmission gear158to rotate faster along the current rotation direction, and the first transmission gear155drives the first auxiliary gear132engaged with the first transmission gear155to rotate faster along the anticlockwise direction. In this case, under the action of the external torque in the same direction, the rotation speed of the first auxiliary gear132along the anticlockwise direction is greater than the rotation speed of the first main gear131along the anticlockwise direction. The rotation speed of the first main gear131along the anticlockwise direction is determined by the output torque of the driving motor110transmitted through the first set of transmission gears121. Because the first auxiliary gear132moves relatively relative to the first main gear131along the anticlockwise direction, as shown inFIG.9, the boss138leaves the second closed end137bof the limiting groove137, and slides along the limiting groove137. During the sliding, the clutch mechanism130enters the separated state, the output torque of the driving motor110cannot be transmitted to the door shaft203due to the disconnection of the transmission link. Therefore, the door shaft203may move casually under the action of the external torque without being affected by the output torque of the driving motor110. Therefore, in the scenarios shown inFIG.8andFIG.9, accelerating the closing of the door may be implemented by manual operation of the user on a basis of automatic closing of the door at a constant speed. In still another typical application scenario, when a turning angle (may also be referred to as a rotation angle) of the door shaft203is zero, that is, when the door body202is located at the closing location, the clutch mechanism130may be in the first engaged state shown inFIG.4, to implement the automatic door opening function in time when an automatic door opening instruction is received. Alternatively, when the door body202is located at the closing location, the clutch mechanism130may be in the separated state shown inFIG.9, to provide a certain free opening angle to flexibly meet the user requirement. When the automatic door opening instruction is received at the location, the driving motor110controls, by outputting a proper output torque, the first main gear131to rotate clockwise to the location shown inFIG.7, so that the boss138abuts against the first closed end137aof the limiting groove137, to further implement the automatic door opening function. Similarly, when the turning angle of the door shaft203is a maximum rotatable angle, that is, when the door body202is located at the maximum opening location, the clutch mechanism130may be in the second engaged state shown inFIG.8, to implement the automatic door closing function in time when an automatic door closing instruction is received. Alternatively, when the door body202is located at the maximum opening location, the clutch mechanism130may be in the separated state shown inFIG.9, to provide a certain free opening angle to flexibly meet the user requirement. When the automatic door opening instruction is received at the location, the driving motor110controls, by outputting a proper output torque, the first main gear131to rotate anticlockwise to the location shown inFIG.8, so that the boss138abuts against the second closed end137bof the limiting groove137, to further implement the automatic door closing function. In actual application, by adjusting the provided angle of the limiting groove137along the circumferential direction of the first main gear131, and/or the width of the boss138along the circumferential direction of the first auxiliary gear132, the maximum angle at which the first main gear131and the first auxiliary gear132can rotate relatively may be adjusted, to further adjust the maximum angle of the automatic door. It should be noted that, although the clockwise rotation direction is used as the opening direction in this embodiment for description, in actual application, a person skilled in the art may flexibly adjust an association relationship between the rotation direction and/or the opening/closing direction of the first main gear131and the first auxiliary gear132, which is not repeated herein. In an embodiment, referring toFIG.2andFIG.10toFIG.13, the automatic door device100may further include a torque control mechanism150disposed on the transmission link of the transmission system120. When the door shaft203is subjected to an external torque in a reversed direction, the torque control mechanism150is adapted to disconnect the transmission link. The reversed direction refers to being in the reversed direction with the torque applied by the transmission system120to the door shaft203. Therefore, when the rotation direction of the door body202applied by the user and the rotation direction of the door shaft203applied by the driving motor110are reversed, the transmission link can be disconnected by the torque control mechanism150, to protect the driving motor110and the transmission system120. In an embodiment, the torque control mechanism150may include: a second main gear151, coupled to the last gear in the first set of transmission gears121; a second auxiliary gear, disposed coaxially with the second main gear151and coupled to the input end130aof the clutch mechanism130; and an elastic piece160, adapted to connect the second main gear151and the second auxiliary gear152. For example, the second main gear151may be engaged with the third auxiliary gear142, and the second auxiliary gear152may be engaged with the first main gear131. Further, when a rotation direction of the second main gear151and a rotation direction of the second auxiliary gear152are reversed, and a torque transmitted by the second auxiliary gear152on the elastic piece160is greater than a preset threshold, the second main gear151and the second auxiliary gear152release to disconnect the transmission link. In other words, when the rotation directions of the second main gear151and the second auxiliary gear152are the same, or although the rotation directions are reversed but the transmitted torque is less than the preset threshold, the second main gear151and the second auxiliary gear152rotate synchronously, and there is no relative rotation between the two gears in the circumferential direction. In this case, the transmission link is in a connection state. When the rotation directions of the second main gear151and the second auxiliary gear152are reversed, and the transmitted torque is greater than the preset threshold, the second main gear151and the second auxiliary gear152release under the action of the elastic piece160, and relative rotation is generated between the two gears in the circumferential direction to disconnect the transmission link. Therefore, the transmission link can be actively disconnected when the torque is excessive due to abnormal operation, to protect the driving motor110and the transmission system120, and prolong the service life of components. For example, referring toFIG.12andFIG.13, a plurality of protruding portions161are disposed on one side of the second auxiliary gear152facing the second main gear151, and the protruding portions161are adapted to clamp the elastic piece160. In a clamped state, the second auxiliary gear152and the second main gear151rotate along the same direction and there is no relative rotation between the two gears. The case in which the direction that the first main gear131rotates clockwise is the opening direction is still used as an example. During automatic opening of the door, as shown inFIG.7, the boss138abuts against the first closed end137aof the limiting groove137all the time. In this case, if the user intends to close the door, the door body202is subjected to an external torque in the reversed direction. The external torque is transmitted to the first auxiliary gear132through the second set of transmission gears122, and because the boss138already abuts against the first closed end137aof the limiting groove137, the external torque acts on the first main gear131in real time to make the first main gear131basically stop rotating. Further, the external torque to which the first main gear131is subjected is transmitted to the second auxiliary gear152engaged with the first main gear131, so that the rotation direction of the second auxiliary gear152and the rotation direction of the second main gear151under the action of the output torque of the driving motor110are reversed. When the reversed transmitted torque is greater than the preset threshold, the elastic piece160is separated from the protruding portions161, to make the second main gear151and the second auxiliary gear152release. In this case, the transmission link is disconnected. On one hand, the user may casually operate the opening/closing direction and speed, and on the other hand, the reversed external torque may not act on the driving motor110, thereby implementing the effect of protecting the driving motor110and the transmission system120. Further, when the second auxiliary gear152rotates to a location at which one protruding portion161on the second auxiliary gear152matches with the location of the elastic piece160again, the elastic piece160automatically falls back to clamp the protruding portion161. In this case, the transmission link is connected again. Similarly, during automatic closing of the door, as shown inFIG.8, the boss138abuts against the second closed end137bof the limiting groove137all the time. In this case, if the user intends to open the door again and applies a reversed external torque to the door body202, through the cooperation of the elastic piece160, the second main gear151and the second auxiliary gear152may release as well, to achieve the effect of protecting the driving motor110and the transmission system120. Further, the torque control mechanism150is further adapted to protect the driving motor110and the transmission system120when the door is excessively opened. For example, in a case of the location shown inFIG.7, when the door shaft203already rotates to the maximum opening angle, if the direction of the subjected external torque is still the opening direction, the second main gear151and the second auxiliary gear152may be controlled by using the elastic piece160to release, to achieve the effect of protecting the driving motor110and the transmission system120. Further, the torque control mechanism150is further adapted to protect the driving motor110and the transmission system120when the external torque in the same direction is excessive. For example, during clockwise rotation, under the action of the external torque in the same direction, when the boss138moves from the first closed end137aof the limiting groove137shown inFIG.7to abut against the second closed end137bof the limiting groove137shown inFIG.8through the location shown inFIG.9, if the external torque in the same direction is still acting, the first auxiliary gear132may in turn drive the first main gear131to rotate. In this case, although the transmitted torque to which the second auxiliary gear152engaged with the first main gear131is subjected and the output torque of the driving motor110to which the second main gear151is subjected are in the same direction, when the transmitted torque to which the second auxiliary gear152is subjected is greater than the preset threshold if the external torque in the same direction is greater, the second main gear151and the second auxiliary gear152may be controlled by using the elastic piece160to release as well, to achieve the effect of protecting the driving motor110and the transmission system120. In this case, during the automatic opening of the door, in a case that the user opens the door vigorously, the transmission link can be disconnected in time by the torque control mechanism150, to prevent the transmission system120and the driving motor110from being damaged by the excessive external torque in the same direction while ensuring that the user to open the door softly. Similarly, during the automatic opening of the door, in a case that the user closes the door vigorously, the transmission link may be disconnected in time by the torque control mechanism150as well, to prevent the transmission system120and the driving motor110from being damaged by the excessive external torque in the same direction while ensuring that the user to close the door softly. In an embodiment, referring toFIG.2andFIG.13, the quantity of the elastic pieces160may be 3 and the elastic pieces are clamped between the protruding portions161of the second auxiliary gear152in a uniformly distributed manner at an interval of 120 degrees. In actual application, the preset threshold may be adjusted by adjusting the quantity and the elastic force of the elastic pieces160. Therefore, based on the elastic cooperation structure formed by the elastic pieces160, the second main gear151, and the second auxiliary gear152, the transmission link of the transmission system120may be disconnected when the torque is excessive due to abnormal operation. Further, a maximum torque for releasing may be freely set according to the elastic force and the quantity of the elastic pieces160, to protect the entire automatic door device100when the load is excessive. In an embodiment, referring toFIG.1andFIG.2again, the automatic door device100may further include a control module170. The control module170is coupled to the driving motor110, and the driving motor110determines an output torque according to a driving instruction sent by the control module170. Therefore, the running state of the driving motor110is adjusted by the control module170, to implement the automatic door function. Specifically, a first fixing portion171may be disposed on the bottom cover102, and is adapted to accommodate and fix the control module170. In a typical application scenario, in response to the external torque in a reversed direction to which the door shaft203is subjected, the control module170may send an updated driving instruction to instruct the driving motor110to output a reversed output torque. Therefore, when a reversed operation of the user to the door body202is sensed, the driving motor110is controlled in time to adjust the output torque, so that the driving direction of the transmission system120to the door shaft203meets user expectation. For example, it is assumed that the control module170receives a door opening instruction sent by the user, the control module170generates a corresponding driving instruction and sends the instruction to the driving motor110, and in response to the driving instruction, the driving motor110outputs a suitable output torque to drive the door shaft203to rotate through the transmission system120, to implement automatic opening of the door. In this process, the user suddenly intends to close the door and directly operates the door body202to move toward the direction for closing the door. In this case, the door shaft is subjected to the external torque in the reversed direction, the boss138abuts against the first closed end137aof the limiting groove137, and the transmitted torque for the first auxiliary gear132is disconnected under the action of the torque control mechanism150. Meanwhile, because the boss136abuts against the first closed end137aof the limiting groove137, the resistance to which the transmission system is subjected is increased, and the current on the driving motor110is correspondingly increased. The control module determines that the door body202is subjected to the external torque in the reversed direction when the increase of the current is detected. Further, the control module170generates an updated driving instruction to instruct the driving motor110to output a data torque of which the direction is reversed to that of the foregoing output torque, so that the first main gear131can rotate along the direction reversed to the foregoing rotation direction. That is, the first main gear rotates, in the same direction with the reversed external torque, to make the boss138at least separated from the first closed end137aof the limiting groove137, so that the door body202may be in a freely opened/closed state. In other words, when it is detected that the door shaft203is subjected to an external torque in a reversed direction, the clutch mechanism130is controlled to enter a separated state by using the control module130, to better meet the user requirement. Further, the updated driving instruction of the control module130is further adapted to enable the output torque in a reversed direction of the driving motor110to support the first main gear131to move to the second closed end137bof the limiting groove137to abut against the boss138, so that the door shaft203can be closed automatically. Therefore, during automatic opening of the door, it may be switched to an automatic door closing state in time due to the reversed closing operation of the user. In an embodiment, referring toFIG.1,FIG.2, andFIG.14, the automatic door device100may further include an angle sensing module180, coupled to the door shaft203and the control module170, and adapted to sense and send a rotation angle of the door shaft203to the control module170. Therefore, the location of the door body202is detected in real time by the angle sensing module180, and the control module170can determine the running state of the driving motor110and/or the real-time state of the clutch mechanism130according to the real-time location of the door body202, to implement different actions according to different locations of the door body202. Further, the angle sensing module180may include: a third transmission gear181, rotating with the door shaft203synchronously; and an angle sensor182, connected to the third transmission gear181, to sense a rotation angle of the third transmission gear181. Therefore, the rotation angle of the door shaft203can be precisely detected by using the third transmission gear181, to determine the real-time location of the door body202. Specifically, the third transmission gear181is engaged with the second transmission gear158. Therefore, the third transmission gear181and the second transmission gear158rotate synchronously, so that the rotation angle of the door shaft203can be accurately collected by the angle sensor182through the second transmission gear158and the third transmission gear181. Further, one side of the third transmission gear181facing the bottom cover102includes a fixing shaft, a third through hole182is provided on the angle sensor182, and the fixing shaft passes through the third through hole194and is then inserted into the accommodating hole provided on the sixth accommodating portion182, to fix the third transmission gear181and the angle sensor182. In a variant, the third transmission gear181may be omitted. That is, the angle sensor182may be directly coupled to the second transmission gear158, to accurately detect the rotation angle of the door shaft203. Alternatively, the third transmission gear181may include one or more gears engaged with each other sequentially, to implement effective transmission of the rotation angle of the door shaft203. In an embodiment, the relative locations of the first main gear131and the first auxiliary gear132may be given freely according to the cooperation between the control module130and the angle sensing module180. For example, when the door shaft203is in a static state, the first main gear131may be controlled to move to make the location of the boss138in the limiting groove137be as shown inFIG.9, so that the door body202both have a certain automatic movement distance in the opening and closing directions. Further, the location of the door body202may be fed back to the control module170in real time according to the cooperation between the control module170and the angle sensing module180. Because the door shaft203is coupled to the first auxiliary gear132, the angle sensing module180may transmit the location of the first auxiliary gear132to the control module170in real time. Correspondingly, the control module170may control the driving motor110to adjust the location of the first main gear131relative to the first auxiliary gear132, to control the connection or disconnection of the transmission link. In an embodiment, when the rotation angle of the door shaft203is not zero and the door shaft203is in the static state for preset duration, the control module170may generate the driving instruction, and the driving instruction is adapted to control the driving motor110to output an output torque along the closing direction, to drive, through the transmission system120, the door shaft203to rotate to close the door shaft202. Therefore, automatic closing of the door body202can be implemented in a case that the door is not closed in a long time, to achieve effects of energy saving and environmental protection. The rotation angle of the door shaft203refers to an angle rotating by using a location at which the door body202closes the body201of the household appliance as a starting location. Preferably, the preset duration may be 5 minutes. In actual application, a person skilled in the art may adjust the specific value of the preset duration according to requirements, to meet power-saving requirements in different application scenarios. In an embodiment, when the rotation angle of the door shaft203is a first preset angle and a door closing instruction sent by a user is received, a first reminding signal is sent. Therefore, when the door closing instruction sent by the user is not adapted to the current location of the door body202, a first reminding signal may be sent to remind the user to modify the door closing instruction in time, to prevent the user from performing wrong operation to damage the door body202, thereby prolonging the service life of the door body202. For example, when the angle sensing module180detects that the rotation angle of the door shaft203is zero, that is, when the door body202is located at the closing location, if the door closing instruction is received, the control module170does not respond to the door closing instruction and sends the first reminding signal, to remind the user that the door body202is already located at the closing location. In this example, the first preset angle may be 0°. In an embodiment, when the rotation angle of the door shaft203is a second preset angle and a door opening instruction sent by a user is received, a second reminding signal is sent. Therefore, when the door opening instruction sent by the user is not adapted to the current location of the door body202, a reminding signal may be sent to remind the user to modify the door opening instruction in time, to prevent the user from performing wrong operation to damage the door body202, thereby prolonging the service life of the door body202. For example, when the angle sensing module180detects that the rotation angle of the door shaft203is a maximum rotatable angle, that is, when the door body202is opened to the maximum angle, if the door opening instruction is received, the control module170does not respond to the door opening instruction and sends the second reminding signal, to remind the user that the door body202is already located at the maximum opening location. In this example, the second preset angle may be the maximum opening angle of the door body202, such as 120°. In an embodiment, a trigger manner of the door closing instruction and/or the door opening instruction may be selected from: key pressing, voice input and motion sensing. Therefore, the operation methods of the user are enriched by using various instruction trigger manners, thereby improving the operation convenience of the user and optimizing the user experience. For example, the motion sensing may include preset gestures, and when it is sensed that the user makes a preset gesture, the control module170generates a corresponding driving instruction. In an embodiment, referring toFIG.1andFIG.2again, the automatic door device100may further include a speed monitoring module190, coupled to the control module170, and adapted to monitor and send running parameters of the driving motor110to the control module170. Therefore, the running parameters of the driving motor110can be detected in real time and fed back to the control module170, so that the control module170can properly adjust the running state of the driving motor110according to the real-time running parameters of the driving motor110, to make the automatic door control for the door shaft203meet the user expectation. Specifically, a second fixing portion191may be disposed on the bottom cover102, and is adapted to accommodate and fix the speed monitoring module190. Preferably, the speed monitoring module190may include a Hall sensor, to precisely detect the running parameters of the driving motor110. Further, the automatic door device100may further include a magnet115. The magnet115rotates synchronously with the driving motor110, and is adapted to cooperate with the Hall sensor. The Hall sensor may determine the rotation speed and the rotation direction of the driving motor110by sensing the rotation direction and the rotation speed of the magnet. In an embodiment, the control module170may determine an updated driving instruction and send the instruction to the driving motor110according to the rotation angle of the door shaft203and the running parameters of the driving motor110, to make a running speed of the door shaft203maintain constant. The updated driving instruction may include updated running parameters. Therefore, a stable door opening/closing speed can be implemented under different loads. For example, during a single time of opening/closing of the door, based on the cooperation between the angle sensing module180and the speed monitoring module190, the control module170may adjust the rotation speed of the driving motor110according to the real-time rotation angle of the door shaft203fed back by the angle sensing module180, to control the output torque of the driving motor110, to make the rotation speed of the door shaft203maintain constant. For another example, for door bodies202with different loads, based on the cooperation between the respective angle sensing module180and the speed monitoring module190, the corresponding control module170may properly determine the current rotation speed of the door shaft203, to ensure that the door bodies202with different loads can open/close the door at a same and constant speed. It should be noted that the solution of this embodiment may be adapted to an automatic door design for a sliding door as well. Specifically, the angle sensing module180is replaced with a location sensing module by connecting an external sliding track at the door shaft203, to simply and conveniently implement the automatic door function of the sliding door. FIG.15is a schematic diagram of a household appliance according to an embodiment of the present invention. Specifically, the household appliance200may include a body201and a door body202connected to the front of the body201, and further includes a door shaft203. The door shaft203is adapted to hinge the body201and the door body202, and the door body202may rotate around the door shaft203. Further, the household appliance200may further include an automatic door device100described above, and the automatic door device100is coupled to the door shaft203to drive the door shaft203to rotate. For example, the door shaft203is adapted to pass through the second through hole159shown inFIG.1, to be coupled to the automatic door device100. Therefore, by adopting the solution of this embodiment, the household appliance200is equipped with the automatic door device100, which can implement an automatic door function. Further, a clutch mechanism130is integrated in the automatic door device100, and may actively disconnect the transmission link from the driving motor110to the door shaft203when a user needs to operate the door body202manually, so that the user does not feel the resistance of the driving motor110and the transmission system120during manual operation, thereby optimizing user experience. In an embodiment, the door body202may include a door end cover204, the door end cover204may include a shaft hole205to receive the door shaft203, and the door end cover204is further adapted to accommodate the automatic door device100. Therefore, according to the design in which the automatic door device100is integrated in the door end cover204, the automatic door device100is in an invisible state to the outside, which facilitates the overall appearance of the household appliance200. For example, during assembly, after the door shaft203passes through the automatic door device100, the automatic door device100may be placed at a suitable location of the door body202, and then the automatic door device100is sealed by using the door end cover204. One end of the door shaft203along the length direction stretches into the door body202, and the other end stretches into the shaft hole205of the door end cover204. The door end cover204is fixed to the body201, to rotatably fix the door body202to the front of the body201. In an embodiment, a rotation angle of the door shaft203may be equal to a rotation angle α of the door body202. In a variant, the door body202may further be a door of a drawer, and the automatic door device100cooperates with a sliding track of the drawer, to implement a detachable automatic door function. In actual application, in addition to the refrigerator shown inFIG.15, the household appliance200of this embodiment may further be a dishwasher, a cooker hood, and the like. The automatic door device100is adapted to cooperate with any door body component that needs to be separated from or combined with the body of the household appliance200in the foregoing household appliance200, to implement the detachable automatic door function. Although specific implementation solutions are described in the foregoing content, these implementation solutions are not intended to limit the scope of the present disclosure, and a single implementation solution for describing a specific feature is the same. The feature embodiments provided in the present disclosure are exemplary rather than restrictive unless different expressions are made. In specific implementation, one or more technical features of dependent claims and technical features of independent claims may be combined, and technical features from corresponding independent claims may be combined in any suitable manner rather than merely according to the specific combinations listed in the claims. Although the present invention is disclosed as above, the present invention is not limited thereto. A person skilled in the art may make various modifications and replacements without departing from the spirit and scope of the present invention. Therefore, the protection scope of the present invention should be subject to the scope limited by the claims. | 53,302 |
11859429 | DETAILED DESCRIPTION Hereinafter, exemplary implementations of the present disclosure will be described in detail with reference to the accompanying drawings. However, the disclosure may, however, be implemented in many different forms and should not be construed as being limited to the implementations set forth herein; rather, alternative implementations included in other retrogressive disclosures or falling within the spirit and scope of the present disclosure can easily be derived through adding, altering, and removing, and will fully convey the concept of the disclosure to those skilled in the art. FIG.1is a perspective view of a refrigerator according to an implementation of the present disclosure. AndFIG.2is a front view illustrating a state in which all doors of the refrigerator are opened. AndFIG.3is a perspective view illustrating a state in which a sub-door of the refrigerator is opened. As illustrated in the drawings, an exterior of a refrigerator1according to an implementation of the present disclosure may be formed by a cabinet10which forms a storage space, and a door which opens and closes the storage space. An inside of the cabinet10may be vertically divided by a barrier11, and a refrigerating compartment12may be formed at an upper portion of the cabinet10, and a freezer compartment13may be formed at a lower portion of the cabinet10. And various accommodation members121such as a shelf, a drawer and a basket may be provided inside the refrigerating compartment12. A main lighting unit85which illuminates the refrigerating compartment12may be provided at the refrigerating compartment12. The main lighting unit85may be disposed at the freezer compartment13, and may also be disposed at any positions of an inner wall surface of the refrigerator1. A drawer type freezer compartment accommodation member131which is inserted into and withdrawn from the freezer compartment13may be mainly disposed inside the freezer compartment13. The freezer compartment accommodation member131may be formed to be inserted and withdrawn, interlocking with opening of a freezer compartment door30. And a first detection device92which detects a user's body may be provided at a front surface of the freezer compartment door30. Detailed description of the first detection device92will be described again below. The door may include a refrigerating compartment door20and the freezer compartment door30. The refrigerating compartment door20serves to open and close an open front surface of the refrigerating compartment12by rotation, and the freezer compartment door30serves to open and close an open front surface of the freezer compartment13by rotation. And one pair of the refrigerating compartment door20and the freezer compartment door30may be provided left and right to shield the refrigerating compartment12and the freezer compartment13. A plurality of door baskets may be provided at the refrigerating compartment door20and the freezer compartment door30. The door baskets may be provided so as not to interfere with the accommodation members121and131while the refrigerating compartment door20and the freezer compartment door30are closed. Meanwhile, the implementation of the present disclosure describes an example in which a French type door opening and closing one space by rotating one pair of doors disposed in parallel is applied to a bottom freezer type refrigerator having the freezer compartment provided at a lower side thereof. However, the present disclosure may be applied to all types of refrigerators having the door. An exterior of each of the refrigerating compartment door20and the freezer compartment door30may be formed of a metallic material, and the entire refrigerator1may have a metallic texture. And if necessary, a dispenser which dispenses water or ice may be provided at the refrigerating compartment door20. Meanwhile, a right one (inFIG.1) of the pair of refrigerating compartment doors20may be formed to be doubly opened and closed. Specifically, the right refrigerating compartment door20may include a main door40which is formed of the metallic material to open and close the refrigerating compartment12, and a sub-door50which is rotatably disposed inside the main door40to open and close an opening of the main door40. The main door40may be formed to have the same size as that of a left one (inFIG.1) of the pair of refrigerating compartment doors20, may be rotatably installed at the cabinet10by a main hinge401and a middle hinge402, and thus may open and close a part of the refrigerating compartment12. And an opening part403which is opened to have a predetermined size may be formed at the main door40. A door basket404may be installed at a rear surface of the main door40including an inside of the opening part403. Therefore, a user may have access to the door basket404through the opening part403without opening of the main door40. At this point, the size of the opening part403may correspond to most of a front surface of the main door40except a part of a perimeter of the main door40. The sub-door50is rotatably installed inside the opening part403, and opens and closes the opening part403. And at least a part of the sub-door50may be formed of a transparent material like glass. Therefore, even while the sub-door50is closed, it is possible to see through the inside of the opening part403. The sub-door50may be referred to as a see-through door. Meanwhile, a front surface of the sub-door50may be formed to have a controllable light transmittance and reflectivity, and thus may be selectively changed into a transparent or opaque state according to a user's operation. And a door lighting unit49which emits light toward the inside of the opening part403may be provided at an upper portion of the main door40, and may be turned on/off by the user. When there are not any operations while all of the main door40and the sub-door50are closed, the door lighting unit49and the main lighting unit85are maintained in an OFF state. In this state, light outside the refrigerator1is reflected on the front surface of the sub-door40, and the sub-door50may have an opaque black color or may be in a state like a mirror surface. Therefore, an accommodation space of the main door40and an internal space of the refrigerating compartment12are not visible. Therefore, the sub-door50may provide a beautiful and simple exterior having a mirror like texture to the refrigerator1. Also, the exterior may harmonize with the metallic texture of the main door40, the refrigerating compartment door20and the freezer compartment door30, and thus may provide a more luxurious image. However, in a state in which all of the main door40and the sub-door50are closed, the door lighting unit49or the main lighting unit85is turned on by a user's certain operation. While the door lighting unit49or the main lighting unit85is turned on, an inside of the refrigerator1becomes bright, and light inside the refrigerator1may be transmitted through the sub-door50, and thus the sub-door50may become transparent. When the sub-door50is in the transparent state, the accommodation space of the main door40and the internal space of the refrigerating compartment12may be visible. Therefore, the user may confirm an accommodation state of food in the accommodation space of the main door40and the internal space of the refrigerating compartment12without opening of the main door40and the sub-door50. Also, when the sub-door50is in the transparent state, a display unit60disposed at a rear of the sub-door50is in a visible state, and an operation state of the refrigerator1may be displayed to an outside. FIG.4is an exploded perspective view illustrating a state in which the main door and the sub-door are separated from each other. As illustrated in the drawing, an external appearance of the main door40may be formed by an outer plate41, a door liner42and door cap decorations45and46. The outer plate41may be formed of a plate-shaped stainless material, and may be formed to be bent and thus to form a part of a front surface and a perimeter surface of the main door40. The door liner42may be injection-molded with a plastic material, and forms the rear surface of the main door40. And the door liner42may form a space which is in communication with the opening part403, and may have a plurality of door dikes and an uneven structure formed at a perimeter thereof so that the door basket404is installed. A rear gasket44may be provided at a perimeter of a rear surface of the door liner42. The rear gasket44is in close contact with a perimeter of the cabinet10, and prevents a leak of cooling air between the main door40and the cabinet10. The upper cap decoration45and the lower cap decoration46form an upper surface and a lower surface of the main door40. And a hinge installation part451which enables the main door40to be rotatably installed at the cabinet10may be formed at each of the upper cap decoration45and the lower cap decoration46. Therefore, an upper end and a lower end of the main door40are rotatably supported by the main hinge401and the middle hinge402, respectively. And a door handle462may be formed to be recessed from the lower surface of the main door40, i.e., the lower cap decoration46. The user may put a hand into the door handle462, may rotate the main door40, and thus may open and close the refrigerating compartment12. Meanwhile, a door frame43may be further provided between the outer plate41and the door liner42, and may form a perimeter of the opening part403. In a state in which the outer plate41, the door liner42, the door frame43, and the cap decorations45and46are coupled with each other, a foaming solution may be filled inside an internal space of the main door40, and thus an insulation may be formed therein. That is, the insulation may be disposed at a perimeter area of the opening part403, and thus isolate a space inside the refrigerator1from a space outside the refrigerator1. A hinge hole433in which each of sub-hinges51and52for installing the sub-door50is installed may be formed at each of both sides of the door frame43. The hinge hole433may be formed at a position which faces a side surface of the sub-door50, and also formed so that each of the sub-hinges51and52is inserted therein. The sub-hinges51and52may include an upper hinge51and a lower hinge52which are installed at an upper end and a lower end of the sub-door50. The sub-hinges51and52may be formed at the upper end and the lower end of the sub-door50to be recessed, such that the upper hinge51and the lower hinge52are installed therein. And the upper hinge51and the lower hinge52may extend laterally toward the hinge hole433, and may be coupled at an inside of the main door40. Therefore, there is not an interfering structure with the sub-hinges51and52at a gap between the main door40and the sub-door50. And a distance between the main door40and the sub-door50may be maintained in a narrow state, and the exterior may be further enhanced. As described above, the interference with the main door40upon the rotation of the sub-door50may be prevented, while the distance between the main door40and the sub-door50is maintained in the narrow state. And a hinge cover53which shields the upper hinge51and guides access of an electric wire of the sub-door50toward the main door40may be further provided at an upper side of the upper hinge51. Meanwhile, the display unit60may be provided at the opening part403. The display unit60serves to display an operation state of the refrigerator1and also to operate the refrigerator1, and may be formed to be seen from an outside through the sub-door50by the user when the sub-door50is in the transparent state. That is, the display unit60is not exposed to the outside while the sub-door50is in the opaque state, and may display a variety of information to the outside while the sub-door50is in the transparent state. Of course, the display unit60may include a display61which displays state information of the refrigerator1, and various operating buttons62which set the operation of the refrigerator1. The operation of the refrigerator1may be operated by the operating buttons62. The display unit60may be separably provided at a lower end of the opening part403. Therefore, when it is necessary to check or repair the display unit60, the display unit60may be separated. And after the main door40is assembled, the display unit60which is assembled as a separate module may be simply installed. Also, the display unit60which has a necessary function according to a specification of the refrigerator1may be selectively installed. To install and separate the display unit60, a display installing protrusion435which is coupled to a display guide634provided at a side surface of the display unit60may be formed at both inner side surfaces of the opening part403. And a display connection part436for electrical connection with the display unit60may be provided at the lower end of the opening part403. The upper cap decoration45is provided at an upper end of the main door40, and an opening device accommodation part452(inFIG.5) may be formed at the upper cap decoration45to be recessed downward. The opening device accommodation part452may be shielded by a cap decoration cover453. FIG.5is an exploded perspective view illustrating an installation structure of a door opening device according to the implementation of the present disclosure. AndFIG.6is a perspective view of the door opening device when being seen from a lower side. AndFIG.7is an exploded perspective view of the door opening device. As illustrated in the drawings, the opening device accommodation part452may be formed at the upper cap decoration45which forms the upper surface of the main door40. And a door opening device70may be provided inside the opening device accommodation part452. An open upper surface of the opening device accommodation part452is shielded by the cap decoration cover453. A rod hole4511which may be formed toward the cabinet10may be formed at an inner side surface of the opening device accommodation part452. The door opening device70for automatically opening the main door40may be accommodated inside the opening device accommodation part452, and may be formed to be shielded by the cap decoration cover453. The door opening device70includes an upper case71and a lower case72which form an external appearance thereof. A driving motor73and a plurality of gears may be installed at the upper case71and the lower case72, and a push rod77which is moved by the plurality of gears may push the cabinet10and thus may open the main door40. The implementation of the present disclosure describes an example in which the door opening device70is provided at the upper end of the main door40. However, the door opening device70may be provided at the sub-door50and the freezer compartment door30, and may be formed to automatically open the sub-door50and the freezer compartment door30. The upper case71and the lower case72form the external appearance of an upper portion and a lower portion of the door opening device70. And a space in which the plurality of gears and the push rod77are disposed may be provided by coupling the upper case71and the lower case72to each other. Ring installation parts721in which a plurality of mounting rings722are installed may be formed at an outside of the lower case72. The mounting ring722serves to support the lower case72and to enable the lower case72to be seated inside the opening device accommodation part452, and may be formed of a silicone material. Therefore, vibration generated when the door opening device70is driven may be attenuated, and thus a noise may be prevented. The mounting ring722may be formed so that a ring boss454inside the opening device accommodation part452passes therethrough. And a screw which passes through the upper case71is fastened to the ring boss454, and thus the upper case71and the lower case72may be coupled to each other, and the lower case72may also be installed and fixed to an inside of the opening device accommodation part452. The driving motor73may be installed at a lower surface of the lower case72. The driving motor73may be a BLDC type motor which is rotated normally or reversely. Since the BLDC type motor is used as the driving motor73, a speed of the driving motor73may be variably controlled by counting a frequency generating (FG) signal. Therefore, when the door opening device70is driven, a shock generated when the main door40is opened and closed may be relieved through controlling of the speed. In an emergency situation, emergency return of the push rod77or the like may be allowed. The implementation of the present disclosure will describe an example of the BLDC motor in which three hall sensors are provided and three FGs are counted during one revolution. The driving motor73may be installed at the lower surface of the lower case72, and a rotating shaft731of the driving motor73extends to an inside of the lower case72, and a motor pinion732may be provided at the rotating shaft731of the driving motor73. The motor pinion732is provided at an internal space of the lower case72, and may be coupled to a first reduction gear751. An opening device PCB74may be provided at the lower surface of the lower case72. The opening device PCB74may be installed at the lower surface of the lower case72, and may be installed under the push rod77. The opening device PCB74serves to control the driving motor73. A first hall sensor741and a second hall sensor742may be provided at the opening device PCB74. The first hall sensor741is provided at a position at which a magnet774provided at the push rod77is detected when the push rod77is completely inserted therein. And the second hall sensor742is provided at a position at which the magnet774provided at the push rod77is detected when the push rod77is completely withdrawn therefrom. Therefore, the driving motor73may be controlled by the opening device PCB74according to detection signals of the first hall sensor741and the second hall sensor742. The plurality of gears may be disposed in the lower case72to be engaged with each other, and may be installed by a shaft723so as to be rotated between the lower case72and the upper case71. The plurality of gears include reduction gears75and dummy gears76. The reduction gears75may reduce a rotating speed, and then may transmit a force for driving the push rod77. And the dummy gear76serves to ensure a withdrawing distance of the push rod77, and a contact position with the push rod77may be moved by combination of the dummy gears76. Specifically, the motor pinion732is coupled to the first reduction gear751. The first reduction gear751is a gear which is coupled to the motor pinion732having the highest rotating speed, and thus there is the highest probability that the noise is generated. Therefore, the motor pinion732and the first reduction gear751may be formed of an elastomer material having excellent mechanical strength and elastic recovery rate and high thermal resistance. Therefore, the noise between the motor pinion732and the first reduction gear751may be reduced while the mechanical strength required in the motor pinion732and the first reduction gear751is satisfied. The remaining gears may be formed of an engineering plastic material (POM). The first reduction gear751may be connected with a second reduction gear752, the second reduction gear752may be connected with a third reduction gear753, and the third reduction gear753may be connected with a fourth reduction gear754sequentially. Like a general reduction gear, the reduction gears75have a structure in which an input side and an output side thereof are arranged vertically in two stages, and may be formed so that the input side and the output side are in contact with another adjacent gear so as to reduce the speed. An RPM may be controlled through combination of the plurality of reduction gears75, and a force transmitted to the push rod77may be controlled through the controlling of the RPM. Of course, the number of reduction gears75may be adjusted as needed. A first dummy gear761is disposed at the fourth reduction gear754, and the first dummy gear761and the push rod77may be connected by a second dummy gear762. Each of the dummy gears76may have a general spur gear shape, and may be formed to simply transmit a force of the fourth reduction gear754to the push rod77and also to ensure a maximum withdrawing distance of the push rod77by controlling a contact distance with the push rod77. To this end, the dummy gears76may include a plurality of gears having different sizes. Specifically, due to a structural characteristic of the lower case72provided inside the cap decoration45, a width of the lower case72is limited. Therefore, a size of each of the reduction gears75disposed inside the lower case72is also limited. In addition, a length of the push rod77is also limited due to its structure characteristic in which the push rod77is inserted or withdrawn inside the lower case72. In this state, the reduction gears75have the two-stage structure having the input side and the output side. Therefore, the sizes thereof are limited to a predetermined size or more. When the fourth reduction gear754is directly connected to the push rod77, a contact point between the fourth reduction gear754and the push rod77is located at a position which is distant from the main door40due to a diameter of the fourth reduction gear754, and the sufficient withdrawing distance of the push rod77may not be ensured. A position of the contact point for transmitting power of the push rod77should be arranged in a withdrawing direction of the push rod77when possible, and also should be located at a position which is close to the rear surface of the main door40. To this end, the dummy gears76may be arranged between the fourth reduction gear754and the push rod77. When the dummy gears76become bigger within a limited space, the position of the contact point with the push rod77is distant from the rear surface of the main door40. Therefore, the power of the fourth reduction gear754is transmitted to the push rod77using a plurality of dummy gears76having small sizes. That is, the power of the fourth reduction gear754may be transmitted to the push rod77using the first dummy gear761and the second dummy gear762. At this point, a size of the second dummy gear762which is in contact with the push rod77may be formed smaller than that of the first dummy gear761, and may be in contact with the push rod77at a position as close as possible to the rear surface of the main door40. And a part of the lower case72at which the second dummy gear762is located may be recessed outward, and thus a position of the second dummy gear762is located as close as possible to a side of the cabinet10. The push rod77may push the cabinet10, and may open the main door40. And the push rod77may be installed inside the lower case72, and a rack771may be formed at an outer surface of the push rod77so as to be coupled to the second dummy gear762. Therefore, due to rotation of the dummy gears76, the rack771may pass through the rod hole4511, and then may protrude. Due to the size and location of the second dummy gear762, at least half of the rack771may be withdrawn out of the case when the push rod77is actuated by the gears. In some cases, at least half of the rack771may be withdrawn out of the rod hole4511. In some cases, the length of the rack771may be longer than a width of the case in the front-to-rear direction. In some cases, the length of the rack771may be longer than a thickness of the door in the front-to-rear direction. Due to the increased length of the rack771, which is made possible due in part to its curved shaped, the length of the rack771may be greater than or equal to a circumference of the second dummy gear762. The push rod77may be formed smaller than a width of the upper cap decoration45, and may also be formed to have a length which may ensure the withdrawing distance of the main door40. And the push rod77may be formed to extend with a predetermined curvature. Therefore, the push rod77may be maintained in a contacting state with a predetermined point of a front surface of the cabinet10even when the main door40is rotated. Therefore, even when the main door40is rotated, the push rod77may be prevented from being slipped, and may push one point of the cabinet10, and thus may open the main door40. A rod cap78may be formed at a front end of the push rod77. The rod cap78may be formed of rubber or an elastic material, and may be in contact with the cabinet10, may prevent generation of the noise when the push rod77is in contact with the cabinet10, may enhance a contacting force, and thus may effectively transmit a push force of the push rod77to the cabinet10. Also, a size of the outer surface of the push rod77may be formed equal to or larger than that of the rod hole4511. Therefore, the rod cap78may be formed to shield the rod hole4511while the push rod77is completely inserted. A guide groove772may be formed at an upper surface and a lower surface of the push rod77. The guide groove772may be formed along an extending shape of the push rod77, and may also be formed to have the same curvature as that of the push rod77. Guide protrusions714and724which are inserted into the guide grooves772may be formed at the lower case72and the upper case71. Since the guide protrusions714and724are also formed to have the same curvature as that of the push rod77, the push rod77is moved along the guide protrusions714and724upon the inserting and withdrawing of the push rod77. Accordingly, when the push rod77is inserted and withdrawn, the guide protrusions714and724may be maintained in an inserted state into the guide grooves772, and thus the push rod77may be prevented from being moved. And since the movement of the push rod77is prevented, the push rod77may be maintained in an stably engaged state with the second dummy gear762even upon the inserting and withdrawing thereof. A magnet installation part773which accommodates the magnet774may be formed at a rear end of the push rod77. The magnet installation part773may be located just above the first hall sensor741in a state in which the push rod77is completed inserted. And the magnet installation part773may be located just above the second hall sensor742in a state in which the push rod77is completed withdrawn. Therefore, when the push rod77is inserted and withdrawn, a motion of the push rod77may be detected through the first hall sensor741and the second hall sensor742of the opening device PCB74. Meanwhile, a switch magnet455is provided at the opening device accommodation part452. The switch magnet455may be installed and fixed inside the opening device accommodation part452which is in contact with the hinge installation part451. And a reed switch4011may be provided at the main hinge401which is installed at the hinge installation part451. The main hinge401at which the reed switch4011is installed includes the hinge which may be formed of a metallic material and substantially fixes the main door40, and the hinge cover which shields the main hinge401. The reed switch4011is provided at the main hinge401, and maintains a fixed position even when the main door40is rotated. And the switch magnet455is rotated together when the main door40is rotated. Therefore, while the main door40is closed, the reed switch4011is switched on by the switch magnet455, and the switch magnet455becomes distant at a moment when the main door40is opened, and thus the reed switch is switched off. Like this, it may be determined whether the main door40is opened or closed according to the ON/OFF of the reed switch4011, and driving of the door opening device70may be controlled according to the opening and closing of the main door40. That is, since the reed switch4011is switched off in a state in which the main door40is opened, the driving motor73is not operated even when an opening signal of the door opening device70is input, while the main door40is opened. FIG.8is a view illustrating a state of the door opening device when the door is closed. As illustrated in the drawing, while the main door40is closed, the switch magnet455is located at a position which faces the reed switch4011, and thus the reed switch4011is maintained in an ON state. And the push rod77is in a completely inserted state. In this state, the magnet774is located above the first hall sensor741, and thus the first hall sensor741is in the ON state. That is, while a user's operation is not provided, the reed switch4011and the first hall sensor741are maintained in the ON state, and the driving motor73is not rotated. In a state in which the push rod77is completely inserted, the rod cap78shields the rod hole4511, and an end of the push rod77is spaced apart from the front surface of the cabinet10. In this state, when the user performs an operation for operating the door opening device70, the opening signal of the main door40is input, and the driving motor73starts to be driven while being normally rotated. A force generated by the driving of the driving motor73is transmitted to the push rod77by the reduction gears75and the dummy gears76, and the push rod77is moved toward the cabinet10. The end of the push rod77is in contact with the cabinet10by movement of the push rod77. And the push rod77is continuously moved in a contacting state with the cabinet10. The push rod77pushes the cabinet10, and thus the main door40is gradually opened. FIG.9is a view illustrating the state of the door opening device when the door is opened. As illustrated in the drawing, while the push rod77is completely withdrawn, the magnet774is located at the second hall sensor742. When the second hall sensor742is turned on, the opening device PCB74determines that the main door40is rotated at a preset angle, and thus may stop the driving of the driving motor73. In this state, the main door40is opened at a predetermined angle, and thus the user may put his/her elbow therein, and may rotate the main door40. That is, in a state in which the user is holding an object, and thus may not open the main door40with his/her hand, the user may further open the main door40using the elbow or a part of his/her body. For example, by the operation of the door opening device70, the main door40may be opened so that a distance D between the rear surface of the main door40and a front surface of the adjacent refrigerating compartment door20is about 70 mm to 80 mm. At this point, a rotating angle of the main door40may be 24° to 26°, for example 25°. In some cases, the rotating angle of the main door40may depend on a distance between the user and the main door40. For example, the rotating angle to which the door is rotated open may be increased beyond 26° if the user is standing farther away from the refrigerator. During this manual opening operation, the door can be opened to its full range, for example 180° or greater. And the open main door40may be closed after the food is completely accommodated. Then, when a preset time passes, the driving motor73may be rotated reversely, and thus the push rod77which is in a withdrawn state may be automatically returned, and thus may be in a state illustrated inFIG.8. And even in the case in which an obstacle is detected when the main door40is opened, or an external force is exerted while the main door40is opened, the driving motor may be reversely rotated, and thus the push rod77may be returned. Meanwhile, when the user further opens the main door40after the main door40is opened, and thus the reed switch4011is switched off, the user may close the main door40before the preset time passes. In this case, the push rod77may be rapidly returned, and thus may be prevented from colliding with the cabinet10and being broken. FIG.10is a perspective view of the sub-door. AndFIG.11is an exploded perspective view of a lower portion of the sub-door. AndFIG.12is a longitudinal cross-sectional view of the sub-door. As illustrated in the drawings, the sub-door50may be formed in a shape corresponding to that of the opening part403. And the sub-door50may be rotatably installed at the main door40by the sub-hinges51and52to open and close the opening part403. A panel assembly54which may be formed by stacking a plurality of glass layers at regular intervals is provided at the sub-door50, and an inside of the refrigerator1may be selectively seen through the panel assembly54. The panel assembly54may be formed so that the plurality of glass layers are arranged to be spaced apart from each other and thus to form an insulation layer. One of the plurality of glass layers which forms the front surface of the sub-door50may be formed of a half glass material to selectively see through the inside of the refrigerator1. The insulation may be formed at a perimeter of the panel assembly54, and thus may insulate an outer area of the panel assembly54. Side frames55and56which form both side surfaces of the sub-door50may be provided at both sides of the panel assembly54. A handle561of the sub-door50may be formed at one side frame56to be recessed, and the sub-hinges51and52may be fixed to the other side frame55. Sub-cap decorations57and58may be provided at upper and lower portions of the panel assembly54. The sub-cap decorations57and58form an upper surface and a lower surface of the sub-door50, is coupled to the side frames55and56, and form a perimeter of the sub-door50. The sub-hinges51and52may be installed at the sub-cap decorations57and58provided at the upper and lower ends of the sub-door50, respectively. A detection device accommodation part582at which a second detection device81and a knock detection device82are installed may be formed at the sub-cap decoration58which forms the lower surface of the sub-door50. The detection device accommodation part582may be shielded by an accommodation part cover583. The second detection device81which may be installed at the sub-cap decoration58is a device which checks a user' approach, and the knock detection device82is a device which detects the user's knocking operation on the sub-door50. The second detection device81and the knock detection device82may be attached to a rear surface of a front panel541which forms a front surface of the panel assembly54. A bezel5411may be formed along a perimeter of the rear surface of the front panel541. The second detection device81and the knock detection device82may be disposed at the bezel5411which is formed at a lower end of the front panel541. Therefore, when being seen from an outside of the refrigerator1, the second detection device81and the knock detection device82may be disposed to be hidden. At this point, a part of the bezel5411located at a portion at which the second detection device81is disposed is removed, and thus infrared light may be easily transmitted and received. The second detection device81may be located on an extension line of the first detection device92, and may be arranged vertically with the first detection device92. And an installation height of the second detection device81corresponds to the lower end of the sub-door50, and thus an ordinary adult may be detected, but a child having a small height, an animal, or other things smaller than the height of the second detection device81may not be detected. A position sensing device (PSD) may be used as the second detection device81. That is, the second detection device81is formed so that the infrared light is emitted from a light emitting part811, an angle of the reflected light is measured by a light receiving part, and thus a position of the user is recognized. An approach distance which is detected by the PSD may be set, and a detectable distance of the second detection device81is set to less than 1 m, and thus, when the user is located within a distance of 1 m from the front surface of the refrigerator1, it may be recognized that the user is located at a front of the refrigerator1to operate the refrigerator1. Like the knock detection device82, an installation position of the second detection device81corresponds to the lower end of the sub-door50located at an upper side. Since the installation position corresponds to a height of about 1 m from a floor, the child having the small height or other things having the low height may not be detected. A pressing member813may be further provided at a rear of the second detection device81. The pressing member813may be formed to press the second detection device81so that the second detection device81is fixed to the detection device accommodation part582, and also the second detection device81is in close contact with the front panel541. The knock detection device82may be formed to recognize whether the user knocks on the front panel541of the sub-door50. A certain operation of the refrigerator1may be indicated by a knocking operation detected by the knock detection device82. For example, the door lighting unit49may be turned on by the user's knocking operation, and thus the sub-door50may become transparent. The knock detection device82is located at an edge of the front panel541, but an effective input part for the user's knocking operation is not limited thereto. The knock detection device82includes a microphone which detects a sound wave generated by vibration, instead of the vibration itself. Therefore, in a state in which the knock detection device82is in close contact with a medium at which the vibration is generated by the knocking operation, even though the knocking operation is applied to any positions, the sound wave may be transmitted through the continuous same medium, and may be effectively detected. And a position of the knock detection device82may be disposed at one end at which the electric wires may be arranged and a visible area of the sub-door50may also be maximized. That is, an area to which a user's knocking input is applied may be an entire area which is defined by the front surface of the front panel541. Most of the front panel541except a boundary portion thereof is a see-through area which selectively becomes transparent, and the knock detection device82may not be disposed thereat. Therefore, it is preferable that the knock detection device82be located at the area of the bezel5411in the front panel541. In particular, the bezel5411located at an upper end and left and right sides of the front panel541may be minimized by locating the knock detection device82at the lower end of the front panel541rather than both of the left and right sides thereof. By such a shape of the bezel5411, the see-through area may be expanded. Since the knock detection device82is located at the lower end of the front panel541on which a user's eyes are relatively less focused, a wider see-through area may be provided to the user. Since the knock detection device82is located at the area of the bezel5411, is not exposed to an outside, and has a structure which is in close contact with the front panel541, the user's knocking operation may be detected even through the user knocks on any position of the front panel541. Meanwhile, there may be a lot of environmental factors other than the knocking operation in which the vibrations are exerted on the front surface of the front panel541. The front surface of the sub-door50may be vibrated by the shock generated when the main door40and the sub-door50are opened and closed, an external loud noise or the like, and such an input due to the external environments may be recognized as a knock signal. Therefore, a detection device PCB83may be set so that a user's operation which knocks several times on the front surface of the sub-door50may be recognized as a normal knock input. More specifically, the user's operation which knocks several times (e.g., twice) on the front surface of the sub-door50at predetermined time intervals may be recognized as the normal knock input. A case fixing part5832to which a screw for fixing the accommodation part cover583to the sub-cap decoration58is fastened may be formed at one side of the accommodation part cover583. An injection port cover part5831is further formed at the other side of the accommodation part cover583. The injection port cover part5831may be formed on the sub-cap decoration58, and also formed to shield a first injection port5824through which the foaming solution filled to mold an insulation501is injected. When the accommodation part cover583is installed at the sub-cap decoration58, the detection device accommodation part582may be shielded, and the first injection port5824may also be shielded. Meanwhile, a second injection port584through which the foaming solution is injected is further formed at one side of the sub-cap decoration58close to the lower hinge52. The second injection port584may be shielded by a separate injection port cover5841. A first boss5821to which a screw for fixing the second detection device81is fastened, and a second boss5822for fixing the knock detection device82are respectively formed at a bottom surface of the detection device accommodation part582. An electric wire hole5823may be formed at one surface of the detection device accommodation part582. An electric wire L which is connected to the detection device PCB83, the second detection device81and the knock detection device82may pass through the electric wire hole5823and the perimeter of the sub-door50, and may be guided to an outside of the sub-door50through the hinge cover53. FIG.13is a perspective view of the freezer compartment door according to the implementation of the present disclosure. AndFIG.14is an exploded perspective view of the freezer compartment door. One pair of the freezer compartment doors30may be provided left and right, and formed to open and close the freezer compartment13by rotation. A sensing assembly90may be provided at a right one (inFIG.1) of the pair of freezer compartment doors30. The pair of freezer compartment doors30have the same structure as each other, except the sensing assembly90, and thus only the right freezer compartment door30will be described. The freezer compartment door30may include a door plate31, a freezer compartment door liner32, an upper decoration33, and a lower decoration34. And the freezer compartment door30is filled with the insulation. The door plate31forms a front surface and both of left and right side surfaces of the freezer compartment door30, and may be formed by bending a plate-shaped stainless material. In particular, an inclined surface35at which the sensing assembly90is installed may be installed at a lower end of the front surface of the freezer compartment door30. The freezer compartment door liner32forms a rear surface of the freezer compartment door30. The freezer compartment door liner32is injection-molded with a resin material, and may be formed so that an accommodation member is installed at the rear surface of the freezer compartment door30. And the insulation may be filled between the freezer compartment door liner32and the door plate31. The upper decoration33is coupled to the door plate31and the freezer compartment door liner32, and forms an upper surface of the freezer compartment door30. And a freezer compartment door handle331may be formed at the upper decoration33to be recessed downward. The upper decoration33may be formed of the same material as that of the door plate31. The lower decoration34is coupled to the door plate31and the freezer compartment door liner32, and forms a lower surface of the freezer compartment door30. Meanwhile, the door plate31which forms the front surface and both side surfaces of the freezer compartment door30is formed by bending the plate-shaped material. In particular, the inclined surface35may be formed at the lower end of the front surface of the freezer compartment door30. To form the inclined surface35, the door plate31is formed by bending several times the plate-shaped material. And the door plate31may be manufactured so that creases are not generated at an exterior thereof, and diffused reflection does not occur even though the inclined surface35is formed. FIGS.15A to15Eare views sequentially illustrating a molding process of the outer plate of the freezer compartment door. A process of manufacturing the door plate31will be described with reference toFIGS.15A to15E. First, to mold the door plate31, a stainless steel plate as a raw material is machined by a blanking process. The door plate31is molded into a shape illustrated inFIG.15Aby the blanking process of the steel plate. Specifically, by the blanking process, the door plate31includes a front surface part311which forms the front surface of the freezer compartment door30, an inclined part312which forms the inclined surface35at a lower end of the front surface part311, and a side surface part313which forms a side surface of the freezer compartment door30. A recessed part314may be formed at a portion of an upper end of the door plate31at which the front surface part311and the side surface part313are divided from each other. When the front surface part311and the side surface part313are bent, a shape which is able to be coupled to the upper decoration33may be formed by the recessed part314. A cut-away part315may be formed at a portion of a lower end of the door plate31at which the inclined part312and the side surface part313are divided from each other. When the front surface part311, the side surface part313and the inclined part312are bent by the cut-away part315, a door slit36may be formed at a corner portion formed by the inclined part312and the side surface part313. And an installation hole351in which the sensing assembly90is inserted may be formed at the inclined part312by the blanking process. In the door plate31machined by the blanking process, a forming part316may be formed to be bent along an edge of the door plate31by a forming process, as illustrated inFIG.15B. The forming part316forms a portion of the door plate31which is coupled to the upper decoration33and the lower decoration34, and a portion thereof which is coupled to the freezer compartment door liner32. The forming part316may be formed to be bent vertically. At this point, a part of the side surface part313and the inclined part312forming the cut-away part315is not machined by the forming process. In the door plate31machined by the forming process, a boundary portion between the front surface part311and the side surface part313is machined by a primary bending process, as illustrated inFIG.15C. A portion which is machined by the primary bending process is a corner portion at which the front surface and the side surface of the freezer compartment door30are in contact with each other, and may be machined by the bending process to have a predetermined curvature. The bending process is performed until when both side ends of the inclined surface35, i.e., portions which are in contact with the cut-away parts315are bent with the same curvature. The door plate31machined by the primary bending process may be machined by a secondary bending process, as illustrated inFIG.15D. A portion machined by the secondary bending process is a boundary line between the front surface part311and the inclined part312, and may be machined by the bending process to have a predetermined curvature. The inclined surface35may be formed by the secondary bending process. The inclined surface35has a predetermined angle. In the implementation of the present disclosure, the inclined surface35may be formed to have an angle of about 20° to 30° with respect to the front surface of the freezer compartment door30. The angle of the inclined surface35may be set within a range which easily detects the user's operation and prevents misrecognition. By the secondary bending process, a side end of the inclined surface35and an end of the side surface part313are in contact with each other. The door plate31machined by the secondary bending process may be machined by a tertiary bending process, as illustrated inFIG.15E. A portion machined by the tertiary bending process corresponds to one end of the side surface part313which forms the cut-away part315, and is bent with a predetermined curvature. By the tertiary bending process, the door slit36may be formed at accurate intervals. By such processes, an entire shape of the door plate31may be formed. In particular, due to a molding structure of the door slit36, the creases are not generated while the inclined surface35is molded, and a curve by which the diffused reflection occurs is not generated. The completely molded door plate31may be coupled to the upper decoration33and the lower decoration34, and may also be coupled to the freezer compartment door liner32. And the foaming solution is filled inside the freezer compartment door30, and forms the insulation. FIG.16is a partial perspective view of the freezer compartment door. As illustrated in the drawing, the door slit36may be formed at a side surface of the freezer compartment door30close to a bottom hinge37which supports a lower end of the freezer compartment door30, and a covering member38is provided inside the freezer compartment door30to shield the door slit36. The door slit36may be formed at the side surface of the freezer compartment door30, i.e., the side surface part313of the door plate31so as to prevent exposure when being seen from a front of the refrigerator1. And the door slit36may be formed along the inclined surface35at a position close to the inclined surface35so as to enable the inclined surface35to be easily molded. By the door slit36, the creases may be prevented from being generated at the door plate31, and the diffused reflection may be prevented from occurring, even though the inclined surface35is molded. The door slit36may be formed corresponding to a length of the inclined surface35, and may be formed to extend to a lower end of the side surface of the freezer compartment door30. Of course, a position at which the door slit36is formed is not limited to the above-described implementation, and may be formed at various positions, e.g., a corner portion of the side surface of the inclined surface35, or one side of the inclined surface35which enables the inclined surface35to be bent. The covering member38may be installed inside the freezer compartment door30. The covering member38may be in close contact with an inner side surface of the door plate31. At this point, a rib part383of the covering member38is inserted into the door slit36. The rib part383may be formed to have the same length and width as those of the door slit36, and may protrude so as to be on the same plane as that of the side surface of the freezer compartment door30while being installed at the door slit36. Therefore, when the rib part383is inserted into the door slit36, the door slit36is filled, and thus prevented from being exposed. And the covering member38or at least the rib part383may be formed to have the same color as that of the outer plate41. Therefore, the rib part383which is exposed to an outside while being inserted into the door slit36has a sense of unity with the door plate31. FIG.17is an exploded perspective view illustrating a coupling structure of the door plate, the lower decoration and the covering member. AndFIG.18is a partially cut-away perspective view illustrating a coupling state of the door plate, the lower decoration and the covering member. AndFIG.19is a cross-sectional view taken along line19-19′ ofFIG.13. The covering member38and a coupling structure of the covering member38will be described with reference to the drawings. The lower decoration34is formed to correspond to a shape of the lower surface of the freezer compartment door30and thus to form the lower surface of the freezer compartment door30. A plate insertion part341may be formed to be recessed along an edge of each of a front end and left and right side ends of the lower decoration34. The plate insertion part341forms a space in which the forming part316forming a boundary of the door plate31is inserted. A plurality of ribs3411which are inclined to enable the forming part316to be fixed while the forming part316is inserted may be formed inside the plate insertion part341. A plate support part342which extends upward may be formed at a perimeter of the lower decoration34except a rear end thereof. The plate support part342may be formed to be in contact with the door plate31and thus to support the door plate31. And a liner support part343which extends upward may be formed at the rear end of the lower decoration34. The liner support part343is in contact with the freezer compartment door liner32, and support a lower end of the freezer compartment door liner32. An internal space of the freezer compartment door30may form a closed space by the plate support part342and the liner support part343, and the foaming solution may be filled inside the plate support part342, and may form the insulation. And a covering member insertion part344which is formed to have a shape corresponding to that of a lower end of the covering member38may be formed at a side end of the lower decoration34. The covering member insertion part344may be formed at the side end of the lower decoration34to be stepped, and may provide a space in which a lower end of the covering member insertion part344is inserted when the door plate31and the lower decoration34are coupled. And a hinge insertion part345and an electric wire fixing part346which will be described below in detail may be further formed at the lower decoration34. The covering member38may be installed and fixed to the lower decoration34, and may be formed to be in close contact with a corner of one side of the freezer compartment door30close to the hinge insertion part345at which the bottom hinge37is installed. Specifically, the covering member38may include a first surface381which is in contact with the side surface part313of the door plate31, and a second surface382which is in contact with the inclined part312and the front surface part311. And a portion at which the first surface381and the second surface382are in contact with each other is formed to have a curvature corresponding to a bent corner part of the door plate31. A lower end of the first surface381extends downward further than a lower end of the second surface382, and may be inserted into the covering member insertion part344. And the rib part383which protrudes outward may be formed at an outer surface of the first surface381. The rib part383may be formed at a position which is able to be inserted into the door slit36. The second surface382may be formed to be in close contact with the inclined surface35and a front surface, and may be formed to be bent at an angle corresponding to the inclined surface35. And the lower end of the second surface382is located upward further than the lower end of the first surface381, and formed so as not to interfere with the plate support part342. While the covering member38is installed, an entire outer surface of the covering member38may be in close contact with an inner surface of the door plate31, and may be maintained in a closely contacting state with the door plate31by an adhesive. And while the covering member38is installed, the rib part383may pass through the door slit36, and may be exposed to the outside. FIG.20is a perspective view of the lower decoration of the freezer compartment door when being seen from a front. AndFIG.21is a perspective view of the lower decoration when being seen from an upper side. As illustrated in the drawings, a sensing assembly installation part39at which the sensing assembly90is installed may be formed to be recessed from one side of the lower decoration34. The sensing assembly installation part39may be formed at an external space of the plate support part342. Therefore, the sensing assembly90may be installed at the sensing assembly installation part39after or before the foaming solution for forming the insulation is injected into a separate space which is partitioned from the space in which the insulation is formed. The sensing assembly installation part39is disposed at one end opposite to a portion at which the bottom hinge37supporting the freezer compartment door30is installed. That is, the sensing assembly installation part39may be formed at one end close to the pair of freezer compartment doors30. Therefore, the sensing assembly90installed at the sensing assembly installation part39may be located up and down on an extension line of the second detection device81. Also, the installation hole351may be disposed at a front of the sensing assembly installation part39. The sensing assembly installation part39may be in communication with a space, which is formed above the lower decoration34, through an electric wire guide hole348. Therefore, the electric wires L which are connected to the sensing assembly90may be introduced into the lower decoration34through the electric wire guide hole348, and may be guided along an inside of the lower decoration34to a lower cap decoration electric wire hole347which is formed at the other side of the lower decoration34. At this point, a plurality of electric wire fixing parts346may be formed at an inner surface of the lower decoration34in an arrangement direction of the electric wires, and the electric wires L may be maintained in the closely contacting state with the electric wire fixing parts346. Therefore, even while the foaming solution is being injected inside the freezer compartment door30, a position of the electric wires L may not be deviated, but may be fixed. The hinge insertion part345is formed at another side of the lower decoration34which is distant from the sensing assembly installation part39. The hinge insertion part345may be formed to extend upward, and may be formed in a boss shape in which a hinge shaft of the bottom hinge37is accommodated. The lower cap decoration electric wire hole347is formed at a bottom surface of the lower decoration34close to the hinge insertion part345. The electric wires L which are connected to the sensing assembly90may be guided to an outside of the lower decoration34through the lower cap decoration electric wire hole347. At this point, the electric wires L may extend toward the cabinet10via a side of the bottom hinge37, and may be connected to a main control part2. FIG.22is a partial perspective view of the sensing assembly installation part of a lower decoration. As illustrated in the drawing, the sensing assembly installation part39may be formed at one side end of the lower decoration34. The sensing assembly installation part39may be formed to be recessed inward in a minimum depth which forms a space for accommodating the sensing assembly90. That is, the insulation may be formed at a rear of the sensing assembly installation part39, and thus insulation performance of the freezer compartment door30may be maintained. In particular, the sensing assembly90may be installed inside the sensing assembly installation part39so as to be inclined. Therefore, the sensing assembly90having a long length may be installed at a limited inside of the freezer compartment door30while maintaining an insulation space. The plate support part342may be formed along an edge of the sensing assembly installation part39. The sensing assembly installation part39may be formed so that a left surface and a front surface thereof are opened. Therefore, when the lower decoration34is injection-molded, an inside of the sensing assembly installation part39may be easily molded. The sensing assembly installation part39may include an assembly accommodation part391and a connector accommodation part392. The assembly accommodation part391is a space in which the sensing assembly90is accommodated, and may be formed at one side end of the lower decoration34. The assembly accommodation part391may be formed to be inclined, and thus to support a rear surface of the sensing assembly90which is disposed to be inclined with respect to the ground. That is, while the sensing assembly90is completely installed, a rear end of the sensing assembly90is in contact with an inner surface of the assembly accommodation part391. An assembly guide394may be formed at a bottom surface of the assembly accommodation part391. The assembly guide394may be formed in a shape having a plurality of ribs which are continuously disposed at regular intervals. And a plurality of assembly guides394may be formed to have the same shape, and may be formed to connect an inner surface393of the assembly accommodation part391with the bottom surface of the lower decoration34. The assembly guide394may be formed vertically long, and a guide inclined part395may be formed at an end of the assembly guide394which is directed toward the door plate31. The guide inclined part395may be formed at a front end of the assembly guide394to be inclined gradually upward toward the inner surface393of the assembly accommodation part391. The guide inclined part395may include a first inclined part3951which extends from the front end of the assembly guide394, and a second inclined part3952which extends from a rear end of the first inclined part3951to a rear end of the assembly guide394. The first inclined part3951may be formed to have a larger slope than that of the second inclined part3952. Therefore, when the sensing assembly90is installed, rear ends of cases93and94may be in contact with the first inclined part3951, and may be moved backward, and may also be easily inserted into the inner surface393of the assembly accommodation part391. The slope of the second inclined part3952may be the same as that of the sensing assembly90when the sensing assembly90is completely installed. That is, when the sensing assembly90is installed, a lower end of the sensing assembly90may be supported by the second inclined part3952, and the sensing assembly90is completely inserted along the second inclined part3952. And in a state in which the sensing assembly90is completely inserted, the lower end of the sensing assembly90is supported, and an installed position of the sensing assembly90is not changed. The connector accommodation part392may be formed at a lateral side of the assembly accommodation part391. The connector accommodation part392forms a space in which sensing assembly connectors912and922for connecting the sensing assembly90with the main control part2are accommodated. Therefore, the connector accommodation part392may be formed to have a size relatively smaller than the assembly accommodation part391. And the electric wire guide hole348may be formed above the connector accommodation part392. Therefore, when the sensing assembly90is installed, a first connector912connected to the sensing assembly90and a second connector922connected to the main control part2are first connected from an outside of the freezer compartment door30, and then the sensing assembly90is inserted into the assembly accommodation part391. At this point, the first connector912and the second connector922which are connected to each other are located at a side of the connector accommodation part392. FIG.23is a perspective view of the sensing assembly according to the implementation of the present disclosure when being seen from a front. AndFIG.24is a perspective view of the sensing assembly when being seen from a rear. AndFIG.25is an exploded perspective view of the sensing assembly when being seen from one direction. AndFIG.26is an exploded perspective view of the sensing assembly when being seen from another direction. AndFIG.27is a longitudinal cross-sectional view of the sensing assembly. As illustrated in the drawings, the sensing assembly90includes a projector91which projects an image which induces a user' operation, and the first detection device92which detects the user's operation at an area of the image projected by the projector91. And the projector91and the first detection device92may be formed in one module. More specifically, an external appearance of the sensing assembly90may be formed by the pair of cases93and94, and a case cover95which shields open front surfaces of the cases93and94. And all of the projector91and the first detection device92may be installed inside the cases93and94. At this point, the projector91and the first detection device92are disposed vertically, and the projector91is located under the first detection device92. Since the projector91is located under the first detection device92, a position of the image projected from an appropriate position may be ensured. When the projector91is located above the first detection device92, a projecting distance is relatively elongated, and thus a possibility of misrecognition is increased, and also a quality of the projected image may be degraded. The cases93and94may include a first case93and a second case94which form both left and right sides. The first case93and the second case94are coupled to each other so that the projector91and the first detection device92are accommodated therein. Rear surfaces of the first case93and the second case94may be coupled to each other by a coupling hook941and a hook groove931. The coupling hook941may be inserted into the hook groove931, and the coupling hook941and the hook groove931may be formed at the first case93and the second case94, respectively. And front surfaces of the first case93and the second case94may be may be fixed by coupling of the case cover95. To this end, side hooks932and942may be formed at both side surfaces of the first case93and the second case94, and may be inserted into a hook restriction part951provided at the case cover95so as to be restricted to each other. And a fastening hole943in which a fastening member9431such as a screw and a bolt is inserted may be formed at the second case94, and a fastening boss933in which the fastening member9431is fastened may be formed inside the first case93. A first PCB hole901and a second PCB hole902through which an LED PCB911and a detection device PCB921are exposed may be formed at the rear surfaces of the cases93and94. The first PCB hole901may be formed at a position corresponding to the LED PCB911, and also formed smaller than the LED PCB911. The electric wire L which is connected to the LED PCB911may pass through the first PCB hole901. And the second PCB hole902may be formed at a position corresponding to the detection device PCB921for an operation of the first detection device92. The electric wire L which is connected to the detection device PCB921may pass through the second PCB hole902. The first connector912which is connected to the electric wires L of the LED PCB911and the detection device PCB921may be connected to the second connector922which is connected to the main control part2, and may be disposed at the connector accommodation part392. A film slot934in which a film913having characters or symbols indicated on the image to be projected on a floor surface on which the refrigerator1sits may be formed at one side of the first case93. A width of the film slot934may be formed larger than a thickness of the film913, and thus the film913may be inserted and installed from an outside of the cases93and94into the cases93and94. Since the film913may be formed in a very thin plate shape, when the film913is installed in the cases93and94, and then the first case93and the second case94are assembled, the film913may be pressed or bent and thus may be deformed or damaged. Therefore, to prevent a damage of the film913, a structure in which the film913is inserted from the outside of the cases93and94through the film slot934may be provided. Meanwhile, a film groove944may be formed at an inner surface of the second case94corresponding to the film slot934. The film groove944may be recessed from the inner surface of the second case94so that the film913is inserted therein. Therefore, an end of the film913may be inserted and fixed into a space like a gap formed by the film groove944. The film groove944may be formed to correspond to one end of the inserted film913. And a corner of one end of the film913may be formed to be inclined, and thus may be inserted with directivity, like a SD card. And the film groove944may be formed correspondingly. Therefore, the film913may be inserted in only one direction, and thus the film913may be prevented from being erroneously installed. For example, the film913may be prevented from being reversely installed or being installed at an inaccurate position. And to prevent the film913from being deformed, a reinforcing plate having a corresponding shape may be further provided at a front surface or a rear surface of the film913. The reinforcing plate may be formed of a transparent material through which light is transmitted, and may be formed to have the same shape as that of the film913. The projector91is disposed at a lower portion inside the cases93and94. To dispose the projector91, a projection part930having a circular cross section may be formed inside the cases93and94. The projector91disposed inside the projection part930may include the LED PCB911, the film913and a plurality of lenses914. Specifically, the LED PCB911is located at the rearmost of the cases93and94, and an LED9111mounted on the LED PCB911emits light toward the film913. To fix the LED PCB911, a PCB fixing part935may be formed at the projection part930. The PCB fixing part935may be recessed so that a corner of the LED PCB911is inserted therein. And the film groove944in which the film913is inserted may be formed at a front of the PCB fixing part935. The film groove944may be formed between the LED PCB911and the lenses914. A position of the film groove944may be determined so that the projected image is formed clearly. A plurality of build-down grooves936which extend in forward and backward directions may be formed at a circumference of the projection part930at which the film groove944is formed. The plurality of build-down grooves936may be provided along the circumference of the projection part930, and serves to prevent deformation due to contraction when the cases93and94are injection-molded. The plurality of lenses914may be provided at a front of the film groove944. The plurality of lenses914may be disposed at regular intervals, and may control a focal distance of the projected image by adjusting a distance between the lenses914. Therefore, the distance between the plurality of lenses914may be adjusted so that the image clearly forms on the floor surface on which the refrigerator1is installed. And lens grooves937in which the lenses914are installed may be formed at the projection part930. The distance between the lenses914may be determined according to a distance between the lens grooves937. The plurality of lenses914disposed at the projection part930may be provided. However, it is preferable that three lenses914be used, considering the space of the assembly accommodation part391. The image projected on the floor surface may be further clear by using more lenses914. However, when the number of lenses914is increased, a length of the projector91is increased, and thus there may be a problem that the sensing assembly90may not be installed inside the freezer compartment door30having a limited thickness. A front surface of the projection part930may be formed to be opened. The open front surface of the projection part930may be shielded by the case cover95. And the light which is emitted from the LED9111and passes through the film913and the lenses914may pass through a projecting hole952of the case cover95, and then may be projected on the floor surface. A detection part940may be formed above the projection part930, i.e., an upper portion of the cases93and94. The detection part940is a portion in which the first detection device92is accommodated, and may be formed in a shape corresponding to the first detection device92. The first detection device92serves to detect whether a user's foot is located at an area of the image projected by the projector91, and may use a device which detects a user' approach. For example, like the second detection device81, the PSD sensor which emits and receives the infrared light may be used as the first detection device92. However, a detection distance of each of the first detection device92and the second detection device81may be set different from each other due to a difference in an installation position thereof and an object to be detected. The first detection device92may have a detection distance of 10 cm to 15 cm corresponding to a distance to the floor surface on which the image projected by the projector91is formed. Meanwhile, in the first detection device92, a light emitting part923and a light receiving part924may be disposed up and down. And a barrier925is provided between the first detection device92and the case cover95. The barrier925may be formed so that both ends thereof are in contact with a front surface of the first detection device92and a rear surface of the case cover95, respectively. And the barrier925divides the light emitting part923and the light receiving part924. Therefore, the infrared light emitted from the light emitting part923may be prevented from being reflected by the case cover95and being directed to the light receiving part924. While the sensing assembly90is installed at the inclined surface35of the freezer compartment door30to be inclined, the first detection device92is installed inside the cases93and94to be intersected with the inclined surface35. And the first detection device92and the case cover95are disposed in a direction which are spaced apart from each other and intersected with each other. In this state, when some of the light emitted from the light emitting part923collides with the case cover95, the light may be reflected and then may be introduced into the light receiving part924. However, when the light emitting part923and the light receiving part924are divided by the barrier925, the infrared light emitted by the light emitting part923penetrates the case cover95, and the light reflected by the floor surface or the user may penetrate the case cover95, and then may be introduced into the light receiving part924. The barrier925may be formed inside the cases93and94, and may be integrally formed with the cases93and94. Of course, the barrier925may also be integrally formed with the first detection device92or the case cover95. The open front surface of the detection part940may be shielded by the case cover95. That is, all of the open front surfaces of the projection part930and the detection part940may be shielded by the case cover95. The case cover95may be formed of a transparent material through which the light is transmitted, and the projecting hole952may be formed at a portion thereof corresponding to the projection part930. A protrusion part953may be formed at an area corresponding to each of a circumference of the projecting hole952and the detection part940. A flange954may be formed at the rear surface of the case cover95to extend backward along a perimeter of the case cover95. And the hook restriction part951which extends backward may be formed at both sides of the case cover95. The side hook932formed at the cases93and94is hooked and restricted by the hook restriction part951. A cover fixing hook956which enables the case cover95to be hooked and fixed to the installation hole351may be formed at both sides of the case cover95. By the cover fixing hook956, the sensing assembly90may be maintained in an installed and fixed state to the sensing assembly installation part39. Meanwhile, a decoration plate96is attached on the front surface of the case cover95. The decoration plate86may be formed of the same metallic material as that of the door plate31. And the decoration plate96may be formed to have the same shape as that of the front surface of the case cover95, and also formed to cover the entire front surface of the case cover95. Plate holes961and962in which the protrusion parts953of the case cover95are inserted may be formed at the decoration plate96. Therefore, the decoration plate96may be coupled to the case cover95. When the sensing assembly90is installed, the decoration plate96is exposed through the installation hole351formed at the inclined surface35of the freezer compartment door30, and may have the sense of unity with the door plate31. Meanwhile, a separate clear cover may be further provided at the open projecting hole952. The clear cover may shield the projecting hole952to prevent foreign substances from entering, and may also be formed to transmit the light projected from the projector91. Of course, the case cover95may be formed so that the projecting hole952and the clear cover are not provided, and the light projected from the projector91penetrates the transparent case cover95, and is projected. FIGS.28A to28Care views illustrating an installation process of the sensing assembly. As illustrated in the drawings, to install the sensing assembly90at the freezer compartment door30, while the molding of the freezer compartment door30is completed, as illustrated inFIG.28A, the second connector922provided to the electric wire L connected to the main control part2is taken out through the installation hole351, and then coupled to the first connector912connected to the sensing assembly90. While the first connector912and the second connector922are connected to each other, the first connector912and the second connector922which are coupled to each other are pushed inside the connector accommodation part392, and then the sensing assembly90is inserted into the installation hole351. When the rear surface of the sensing assembly90is inserted into the installation hole351, lower surfaces of the cases93and94are in contact with the assembly guide394. That is, as illustrated inFIG.29B, the lower surfaces of the cases93and94may be moved while being in contact with the first inclined part3951. When the sensing assembly90is continuously pushed in a rear, the lower surfaces of the cases93and94are moved along the second inclined part3952, and rear ends of the cases93and94are in contact with the inner surface393of the assembly accommodation part391, and are in a state illustrated inFIG.28C. While the sensing assembly90is completely inserted and installed, the second inclined part3952supports the sensing assembly90from a lower side. And the case cover95may be fixed in the installation hole351by the cover fixing hook956of the case cover95. And while the fixing and installing of the sensing assembly90is completed, the front surface of the case cover95or the decoration plate96is located on the same plane as that of the front surface of the inclined surface35, and shields the installation hole351. Hereinafter, an image projecting method by the sensing assembly90and a detecting method of the first detection device92will be described. FIG.29is a view illustrating an image projecting state through the projector of the sensing assembly. AndFIG.30is an enlarged view of an A area ofFIG.29. As illustrated in the drawings, a predetermined image is projected on the floor surface, on which the refrigerator1is installed, by the projector91of the sensing assembly90so as to induce the user's operation. The light emitted from the LED9111of the LED PCB911passes through the film913, and the light passes through the film913passes through the plurality of lenses914. The light passing through the lenses914passes through a focal point, and indicates the characters T provided at the film913on the floor surface. At this point, the sensing assembly90has limitation in a length and a size thereof due to structural characteristics of the insulated freezer compartment door30. Therefore, in the projector91, an aspheric lens which enables the light to straightly penetrate the film913may be omitted to increase definition of the image, and thus the size thereof may be reduced. However, due to omission of the aspheric lens, an intensity of the light incident to a surface of the film913may not be constant, and thus the image may not be clearly formed. Therefore, to solve the problems, the intensity of the light is increased by moving the film913toward the LED9111, and the characters T on the film913may be formed in a high-resolution printing method, and thus the characters may be clearly formed on the floor surface. When the image is projected on an inclined floor surface, uniformity of the image indicated on the floor surface is degraded by a difference in the intensity of light due to a difference in the projecting distance between a first half portion and a second half portion. Specifically, due to a characteristic of the light emitted from the inclined surface35of the freezer compartment door30toward the floor surface, a side close to the front surface of the freezer compartment door30has a short projecting distance and thus a high intensity of light, and a side distant from the front surface of the freezer compartment door30has a long projecting distance and thus a low intensity of light. Therefore, there is a problem that a size of the characters T indicated by the image displayed on the floor surface is changed according to whether the image is located close to or distant from the freezer compartment door30. Also, due to the difference in the intensity of light, the characters T formed on the floor surface close to the freezer compartment door30is spread, or the characters T formed on the floor surface distant from the freezer compartment door30becomes dark. To solve the problems, the characters T formed on the film913is compensated, and thus even when the image is projected on the inclined floor surface, the entire characters T may be clearly formed with a normal rate. Specifically, as illustrated inFIG.30, in the characters T printed on the film913, an area of a portion corresponding to a word “Door” is formed widely, and an area of a portion corresponding to a word “Open” is formed narrowly, and thus the entire portion may be formed in a trapezoidal shape. For understanding of the description, the certain characters have been described. However, even in the case of another characters, pictures or figures, the picture or the figure printed on the film913may be formed to have a width which becomes narrower downward. When the light is emitted from the LED9111to the film913on which the characters T are printed as described above, the characters T of the image indicated on the relatively inclined floor surface may be indicated with the same vertical width rate, regardless of the difference in the projecting distance. Also, brightness and definition of the side close to or distant from the freezer compartment door30may be relatively improved, and thus the user may easily recognize the characters T. FIG.31is a view illustrating a detection area and an image projecting area by the sensing assembly. As illustrated in the drawing, the sensing assembly90may be installed at the sensing assembly installation part39. The sensing assembly90may be supported inclinedly by the assembly guide394. And the front surface of the sensing assembly90is located at the inclined surface35of the freezer compartment door30. Therefore, the image may be formed on the floor surface located at a front of the refrigerator1by the light emitted from the projector91, and a corresponding position may be detected by the first detection device92. At this point, all of a position of the image formed on the floor surface and a detection position by the first detection device92may be determined by an angle of the inclined surface35. More specifically, the inclined surface35of the freezer compartment door30may be formed to have an angle of about 20° to 30° with respect to the front surface of the freezer compartment door30. When the inclined surface35has an angle of less than 20°, the image is projected at a too long distance from the freezer compartment13, and thus a shape of the image formed on the floor surface is also unclear or distorted. In particular, the detection distance for detecting the user's operation by the first detection device92is too far, and thus in a situation in which the user does not want a door opening operation, the door opening device70may be operated due to misrecognition. That is, in a situation in which a person or an animal just passes the refrigerator1, or in a situation in which an object is located or moved at a front of the refrigerator1, the situation may be misrecognized as an opening operation of the main door40, and thus the door opening device70may be driven. Also, when the angle of the inclined surface35is more than 30°, the image projected from the projector91is formed at a side which is too close to the front surface of the refrigerator1, and the detection position of the user's operation by the first detection device92is also too close to the freezer compartment door30. In this case, the user should approach a position close to the refrigerator1to operate the main door40. In this state, when the door opening device70is driven, the user may collide with the main door40which is automatically opened. Also, when the inclined surface35has a too large angle, the bottom hinge37, the cover which shields the bottom hinge37or other elements provided at the lower end of the freezer compartment door30may be exposed. And a leg14which supports the cabinet10at a lower surface of the cabinet10may be exposed, and thus the external appearance may be degraded. Considering the situation, it is preferable that the inclined surface35have the angle of about 20° to 30°. In this state, the user's foot may be detected at a distance of 5 cm to 10 cm from the front surface of the freezer compartment door30. Therefore, when the main door40is opened, the user's operation may be performed at a position at which the user does not collide with the main door40. In particular, when the image is projected from the inclined surface35on the floor surface, and the user's foot is moved to a space under the inclined surface35, the user's foot may be detected and thus the possibility of the misrecognition may be considerably reduced. Hereinafter, an operation of the refrigerator1according to the implementation of the present disclosure having the above-described structure will be described. FIG.32is a block diagram illustrating a flow of a control signal of the refrigerator. As illustrated in the drawing, the refrigerator1includes the main control part2which controls the operation of the refrigerator1, and the main control part2may be connected to the reed switch4011. The reed switch4011may be provided at the main hinge401, and may detect the opening of the main door40. And the main control part2may be connected to the main lighting unit85provided inside the cabinet10, and may illuminate the inside of the refrigerator1when the refrigerating compartment door20or the main door40is opened. And the main control part2may be connected to the door lighting unit49, and may turn on the door lighting unit49when the sub-door50is opened or when a signal of the knock detection device82is input. The main control part2may be connected to the display unit50, may control an operation of the display unit60, and may display operation information of the refrigerator1through the display unit60or may operate various functions. The main control part2may be directly or indirectly connected to the first detection device92, the second detection device81, the knock detection device82and the projector91, and may receive an operation signal by them, or may control the operation. And the main control part2may be connected to the door opening device70, and the door opening device70may be driven according to the user's operation so that the main door40is automatically opened. FIGS.33A and33Bare views illustrating an opening operation state of the main door. AndFIG.34is a flowchart sequentially illustrating an operation of the door opening device. As illustrated in the drawings, when electric power is applied to the refrigerator1while the refrigerator1is installed, the refrigerator1may enter a standby state for the opening of the main door40through an initial operation [S100]. In a state in which the initial operation is completed by supplying the electric power, a standby operation is performed. And in the standby operation, the refrigerator1waits to detect the user's operation for opening the main door40. As illustrated inFIG.33A, in a state in which the refrigerator1is in the standby operation, when the user stands in front of the refrigerator1while holding an object in his/her hands, the user's position is recognized by the second detection device81. And when the second detection device81recognizes that the user is located within a detection range, the projector91is operated, and projects the image on the floor surface on which the refrigerator1is installed. In this state, when the user's foot is moved to a lower side of the inclined surface35at which the freezer compartment door30is formed, at least a part of the image projected on the floor surface may be covered, as illustrated inFIG.33B. And the first detection device92may detect that the user's foot is located at the area of the image projected by the projector91, and thus may transmit a signal for opening the main door40[S200]. In the standby operation, when the signal for opening the main door40is input, the door opening device70starts to be driven, and an opening operation in which the main door40is automatically opened is performed, and the main door40is rotated at a preset angle. The main door40which is rotated at the preset angle may be opened so as to be spaced apart from the front surface of the adjacent refrigerating compartment12, and the user may put his/her elbow in an open space, and may further open the main door40. While the main door40is opened, a stopping operation after opening is performed so that the main door40is maintained in an opened state for a preset time. Therefore, the main door40may be maintained in the opened state [S400]. Meanwhile, when the preset time passes after the main door40is opened, the door opening device70performs a returning operation. In the returning operation, the main door40is rotated by its own weight, and shields the refrigerating compartment12. When the refrigerator1is installed, the refrigerator1is disposed to be inclined, such that the front surface thereof is somewhat higher than the rear surface thereof. This is to enable the doors to be closed by their own weights when an external force is removed after the door of the refrigerator1including the main door40is opened. When the returning operation is completed, the refrigerator1is again in the standby operation which detects the user's operation. This process may be repeated, and the refrigerator1is maintained in a standby operation state after the electric power is applied [S500]. Meanwhile, when the main door40is further opened by the user's operation while the main door40is being opened, an emergency returning signal is generated. The door opening device70may perform an emergency returning operation, and thus may rapidly return the push rod77. Therefore, the main door40may be prevented from colliding with the push rod77, and damage of the push rod77or the door opening device70may be prevented [S600]. Hereinafter, each operation state will be described in detail with reference to the drawings. FIG.35is a flowchart sequentially illustrating the initial operation of the door opening device. As illustrated in the drawing, when the initial operation is started, the electric power is applied to the refrigerator1[S110]. When the electric power is applied, it is determined whether the first hall sensor741is in the ON state [S120]. When the first hall sensor741is in the ON state, a normal operation may be performed at an initial state in which the push rod77is completely inserted. Therefore, when the first hall sensor741is in the ON state, the driving motor73is not operated, and the refrigerator1enters the standby operation state [S130]. When the first hall sensor741is not in the ON state, the push rod77is not located at an initial position, and thus the driving motor73is reversely rotated so that the first hall sensor741is in the ON state [S140]. Meanwhile, in a state in which the driving motor73starts to be reversely rotated, if the first hall sensor741is not in the ON state even when the preset time (e.g., 5 seconds) passes, it is determined that the door opening device70is abnormal [S150], and the driving motor73is stopped, and an error signal is generated [S160]. To enable the user to confirm generation of the error signal, the display unit60codes a current state, and then outputs an error code [S170]. FIG.36is a flowchart sequentially illustrating the standby operation of the door opening device. As illustrated in the drawing, when the standby operation is started, first it is determined through the reed switch4011whether the main door40is in a closed state. While the reed switch4011is switched on, the main door40may be automatically opened. However, while the reed switch4011is switched off, the main door40is opened, and thus the door opening device70is not operated [S210]. In a state in which the reed switch4011is in the ON state, the second detection device81first detects the user's approach. At this point, the second detection device81is located at a height of about 1 m from the ground, and the detection distance may be within a range of about 1 m from the front surface of the refrigerator1[S220]. When the second detection device81is turned on, the projector91is also turned on, and the light is emitted from the LED9111, and thus the image is projected to the lower side of the inclined surface35. Therefore, the user may confirm the characters indicated on the floor surface located at a front of the freezer compartment door30, and may move his/her foot to a position of the characters in a state in which his/her hands cannot be used [S230]. At this point, since the area of the image projected on the floor surface is within the detection distance of the first detection device92, when the user's foot is located at the position of the characters, the first detection device92may detect the user's foot. The first detection device92is maintained in a detecting state for a preset time, and when the preset time passes [S240], the detecting state is released, and the projector91is also turned off [S280]. When the user's foot is located at the area of the characters, and the first detection device92detects the user's foot [S250], the main control part2inputs an opening signal of the main door40[S260]. The main door40performs the opening operation by inputting of the opening signal of the main door40[S270]. FIG.37is a flowchart sequentially illustrating the opening operation of the door opening device. AndFIG.38is a view illustrating a duty change according to an FG pulse count during the opening operation. As illustrated in the drawings, when the opening operation is started, the driving motor73is normally rotated [S310]. Movement of the push rod77which is located at the initial position is started by normal rotation of the driving motor73. That is, while the first hall sensor741is in the ON state, the driving motor73is normally rotated until when the second hall sensor742is in the ON state by the movement of the push rod77[S310]. The push rod77may protrude by the normal rotation of the driving motor73, and may push the cabinet10so that the main door40is opened. And the driving motor73may be controlled to be driven while reducing duty. That is, when the driving motor73is driving at the same speed, the main door40may be rolled by inertia at a moment when the opening of the main door40is completed and then the main door40is stopped. However, when a speed of the driving motor73is reduced before the opening of the main door40is completed, rolling of the main door40at a moment when the opening of the main door40is completed may be reduced. As illustrated inFIG.38, the driving motor73may be driven with a duty of 200 at a first opening section O1in which the FG is 270. And the driving motor73may be driven with a duty of 170 at a second opening section O2in which the FG is 300. And the driving motor73may be driven with a duty of 135 at a third opening section O3in which the FG is 325. And the driving motor73may be driven with a duty of 100 at a last fourth opening section O4in which the FG is 340. Like this, at an early stage in which the main door40is opened, the driving motor73may be rotated at the highest speed, and the opening of the main door40may be rapidly performed. As the opening of the main door40is being performed, the rotating speed of the driving motor73is reduced in stages, and thus the rolling of the main door40may be prevented when the opening of the main door40is completed. Meanwhile, in the case in which the second hall sensor742is not turned on even when the preset time (e.g., 5 seconds) passes after the normal rotation of the driving motor73is started, the door opening device70is abnormal, and thus the error signal is generated, and thus a corresponding error code may be output through the display unit60. And since the opening operation of the main door40may not be continuously performed, the returning operation is started. And in a state in which the preset time does not pass after the normal rotation of the driving motor73is started, the opening operation of the main door40is continuously performed [S330]. At this point, when a person or an object is located at a front of the main door40which is close to the main door40, the main door40may be in a state which is not opened. That is, while the opening operation of the main door40is being performed, the opening of the main door40may be obstructed by an external factor [S340]. In such as state, the main door40may not be rotated at a normal or preset rotating speed. Therefore, the main control part2checks the FG counter of the driving motor73, and outputs the error code through the display unit60when the FG counter at each opening section is less than a preset number [S350]. And the main control part2determines that the opening of the main door40is obstructed, and performs the returning operation. Therefore, an impact may be prevented from being exerted to the user by the rotation of the main door40, and the door opening device70may also be prevented from being broken by excessive driving of the door opening device70. Meanwhile, when the push rod77is moved to a position at which the second hall sensor742is turned on, the stopping operation after opening is started. FIG.39is a flowchart sequentially illustrating the stopping operation after opening of the door opening device. As illustrated in the drawing, when the stopping operation after opening is started, the driving motor73is continuously maintained in the normal rotation state. At this point, the driving motor73is operated while maintaining a constant duty in a normal direction. At this point, the duty of the driving motor73is 12 at which the push rod77exerts a force toward the main door40to just support the main door40, such that the main door40is not pushed and closed, and does not further open the main door40[S410]. The driving motor73is maintained in the normal rotation state for a preset time (e.g., 3 seconds), and when the preset time passes, the returning operation is performed [S240]. And the user may push the main door40to close the opened main door40before the preset time passes. Therefore, when an external force is applied to the main door40, the returning operation is performed to protect the door opening device70. At this point, in determining whether the external force is applied to the main door40, when the FG of the driving motor73is 3 or more, and it is determined that the driving motor73is reversely rotated about one revolution, an external force detection signal is input to the main control part2. The main control part2starts the returning operation when the external force detection signal is input [S340]. FIG.40is a flowchart sequentially illustrating the returning operation of the door opening device. AndFIG.41is a view illustrating a duty change during the returning operation according to the FG pulse count. When the door returning operation is started, first, the driving motor73in the normal rotation state is stopped suddenly (e.g., for 10 msec) [S510]. After the driving motor73is stopped, the driving motor73is reversely rotated to return the push rod77[S520]. The refrigerating compartment door20including the main door40may have the French door structure. When the refrigerating compartment door20is closed, resistance is generated by an influence of a which seals between the main door40and the refrigerating compartment door20when the main door40is closed. Therefore, to prevent the main door40from being not completely closed by the filler when the main door40is closed, the main door40is closed at a high speed. And also to prevent a shock and a noise generated when the main door40is closed, the rotating speed is reduced at the moment. As illustrated inFIG.41, in a state in which the opening of the main door40is completed, the FG of the driving motor is 340. The driving motor73is driven with a duty of 200 at a first closing section C1in which the FG is 70. And the driving motor73is driven with a duty of 180 at a second closing section C2in which the FG is 45. And driving motor73is driven with a duty of 140 at a third closing section C3in which the FG is 25. And driving motor73is driven with a duty of 100 at a last fourth closing section C4in which the FG is 0. The push rod77is moved by reverse rotation of the driving motor73, and the second hall sensor742is turned off, and the driving motor73is reversely rotated until the first hall sensor741is turned on. And when the first hall sensor741is turned on, and it is confirmed that the push rod77is returned to the initial position [S530], the driving motor73is stopped, and enters the standby operation state [S540]. Meanwhile, in the case in which the first hall sensor741is not in the ON state even when the driving motor73is reversely rotated for a preset time (e.g., 5 seconds) or more [S550], the door opening device70is abnormal, and thus the error signal is output. And the error code is displayed through the display unit60, and it is returned to the standby operation [S560]. FIG.42is a flowchart sequentially illustrating the emergency returning operation of the door opening device. AndFIG.43is a view illustrating a duty change according to the FG pulse count during the emergency returning operation. The door opening device70may emergently return the push rod77to protect the door opening device70. During the opening operation, or the stopping operation after opening, or the returning operation, the user may further open the main door40. The user may open the main door40under the necessity, and then may also close the main door40under the necessity. At this point, when the main door40is rotated at a high speed, the push rod77may collide with the main door40before the push rod77is returned to the initial position. When the push rod77and the main door40collide with each other at a high speed, the push rod77or the door opening device70may be damaged. Therefore, when the reed switch4011is switched off during the opening operation, or the stopping operation after opening, or the returning operation, it is determined that the main door40is further opened by the user, and the emergency returning operation in which the push rod77is rapidly returned is performed. As illustrated in the drawings, when the emergency returning operation is started, first it is determined whether the driving motor73is in the normal rotation state [S610]. When the driving motor73is in the normal rotation state, the driving motor73in the normal rotation state is stopped suddenly (e.g., for 10 msec) [S620]. After the driving motor73is stopped, the driving motor73is reversely rotated to return the push rod77[S630]. Meanwhile, when the driving motor73is not in the normal rotation state, the driving motor73is reversely rotated. At the same time when the reverse rotation is started, the driving motor73is driven with a duty of 220 which is greater than that in the returning operation. The rotating speed of the driving motor73is maintained just before the main door40is closed, and thus the main door40is rapidly closed. At a section, in which the FG is 25, just before the main door40is closed, the duty of the driving motor73is reduced to 100, and thus the shock at a moment when the main door40is closed may be reduced. The push rod77is moved by the reverse rotation of the driving motor73, and the second hall sensor742is turned off, and the driving motor73is reversely rotated until the first hall sensor741is turned on [S640]. And when the first hall sensor741is turned on, and it is confirmed that the push rod77is returned to the initial position, the driving motor73is stopped, and enters the standby operation state [S650]. Meanwhile, in the case in which the first hall sensor741is not in the ON state even when the driving motor73is reversely rotated for a preset time (e.g., 5 seconds) or more [S660], the door opening device70is abnormal, and thus the error signal is output. And the error code is displayed through the display unit60, and it is returned to the standby operation [S670]. Meanwhile, the refrigerator according to the present disclosure may possible in various other implementations in addition to the above described implementations. Hereinafter, describing the other implementations of the present disclosure. FIG.44is a perspective view of a refrigerator according to a first implementation,FIG.45is a perspective view illustrating a state of a door opening device equipped in a first refrigerating compartment door according to the first implementation,FIG.46is a view illustrating the door opening device according to the first implementation, andFIG.47is a plan view illustrating a state of the door opening device installed on the first refrigerating compartment door according to the first implementation. With reference toFIGS.44to47, a refrigerator1according to the first implementation may include a cabinet10provided with a storage space therein, and a door20coupled to a front surface of the cabinet10in a rotatable or a slidable manner to selectively open and close the storage space. In particular, the storage space may include one or more compartments of a refrigerating compartment12and a freezer compartment13. The refrigerating compartment12may be opened and closed by a refrigerating compartment door20, and the freezer compartment13may be selectively opened and closed by a freezer compartment door30. Also, when the refrigerating compartment door20for opening and closing the refrigerating compartment12is a rotary-type door, the refrigerating compartment door20may be a pair of French-style doors201and202which are rotatably connected to a front left edge and a front right edge of the cabinet10. That is, the pair of French-style doors201and202may include a first refrigerating compartment door201and the second refrigerating compartment door202. When the freezer compartment door30for opening and closing the freezer compartment13is a rotary-type door, the freezer compartment door30may be a pair of French-style doors301and302which are rotatably connected to the front left edge and the front right edge of the cabinet10. Furthermore, if the freezer compartment door30is a drawer-type door for opening and closing the freezer compartment13in a sliding manner, a plurality of freezer compartment doors may be arranged in upward and downward directions or in left and right directions. The refrigerator1may further include a door opening device25which operates to open the refrigerating compartment door20. Hereinafter, the door opening device25automatically opening the first refrigerating compartment door201of the refrigerating compartment door20will be described with an example. The door opening device25may be placed in a door required to be opened. For opening each of a plurality of refrigerating compartment doors, a door opening device may be equipped to each of the plurality refrigerating compartment doors. Or, if one refrigerating compartment door includes a plurality of doors, a door opening device may be equipped to one or all of the plurality of doors. Also, for opening the freezer compartment door30, the door opening device25can be equipped in the freezer compartment door30. In the present implementation, though a bottom freezer type refrigerator is disclosed, the spirit of the present disclosure for opening a door may be applied to various refrigerators including a top mount type refrigerator, a side by side type refrigerator, a refrigerator having a single storage space and single door, etc. without being limited to the type. The first refrigerating compartment door201may be connected to the cabinet10by a hinge401. The first refrigerating compartment door201may be rotated by a hinge shaft4010which provides a center of rotation. The hinge shaft4010may be equipped in the first refrigerating compartment door201and/or the hinge401. The door opening device25may be placed in an upper side portion of the first refrigerating compartment door201. A frame141forming a space for accommodating the door opening device25may be equipped in the upper side portion of the first refrigerating compartment door201. The frame141may partition a space in which an insulator (not shown) is accommodated and a space in which the door opening device25is accommodated, in the first refrigerating compartment door201. As another example, the door opening device25may be placed in a lower side portion of the first refrigerating compartment door201. The door opening device25may include a housing250accommodated in the frame141, a motor261installed in the housing250and generating a driving force, a push rod27which operates by receiving the driving force of the motor261, and an electric power transferring device for transferring the driving force of the motor261to the push rod27. Although it is not limited, the housing250may include a first housing251and a second housing252coupled to the first housing251. A coupling unit253coupled with a buffer unit254which may absorb shock or vibration may be equipped in the first housing251. The buffer unit254may define a hole255and the frame141may have an installation unit142which may be inserted into the hole255of the buffer unit254. As the door opening device25is coupled to the frame141by the buffer unit254, a vibration generated during the operation of the motor261and a vibration generated during the operation of the electric power transferring device are absorbed and a noise may be reduced, and the vibrations of the motor and electric power transferring device may be prevented from being transferred to the first refrigerating compartment door201. The electric power transferring device may include one or more gears262,263,264,265, and266. In the present disclosure, as long as the electric power transferring device transfers the electric power of the motor261to the push rod27, the number of the gears has no limit, and as an example,FIG.47shows an electric power transferring device including a plurality of gears. By one directional rotation of the motor261, the plurality of gears262,263,264,265and266are rotated in a forward direction, and accordingly, the push rod27may move in the direction withdrawn from the first refrigerating compartment door201for opening a door. On the other hand, by the other directional rotation of the motor261, the plurality of gears262,263,264,265and266are rotated in a reverse direction, and the push rod27may be inserted into the first refrigerating compartment door201. At this time, each of the plurality of gears262,263,264,265and266may be a spur gear so that each of the plurality of gears262,263,264,265and266can be rotated in the reverse direction by an external force applied to the push rod27after the opening process of the door or completion of door opening and before the push rod27returns to an initial position. Therefore, even when the external force acts on the push rod27, the plurality of gears262,263,264,265and266may be rotated in the reverse direction and has an advantage to prevent the damage of the plurality of gears262,263,264,265and266and the push rod27. Alternatively, some or all of the plurality of gears may be a multi-stage spur gear having two gear bodies with different diameters. FIG.48is a view illustrating a push rod constituting the door opening device,FIG.49is a view illustrating a state of the push rod ofFIG.48protruding from a frame of the first refrigerating compartment door, andFIG.50is a view illustrating an opening process of a refrigerator door according to the first implementation. With reference toFIGS.46to50, since the push rod27is placed in the first refrigerating compartment door201, the length of the push rod27is limited. In the present disclosure, the push rod27may include a curve-shaped rack gear272so that the first refrigerating compartment door201can be opened using the push rod27arranged in the first refrigerating compartment door201. At this time, the rack gear272may be engaged with a last gear of the plurality of gears262,263,264,265and266. As the rack gear272is formed in a curved shape, the length of the push rod27may be reduced when opening the first refrigerating compartment door201as much as a required angle. Therefore, even if the push rod27is arranged on the first refrigerating compartment door201, the first refrigerating compartment door201can be opened by the push rod27. As the rack gear272is formed in a curved shape, when the last gear of the plurality of gears262,263,264,265and266is rotated, the push rod27may be rotated relative to the last gear. That is, when the motor261operates, the push rod27not only may rotate about the hinge shaft4010with the first refrigerating compartment door201but also rotate about the plurality of gears262,263,264,265and266and consequently, may do a relatively curved motion about the first refrigerating compartment door201. The rack gear272may be formed in an arc shape. In this case, the rack gear272may be arranged to be convex in a direction away from the hinge shaft4010. When the push rod27do the relatively curved motion about the first refrigerating compartment door201, a center of the curve-shaped rack gear272may match the hinge shaft4010for maintaining the push rod27to be in contact with the cabinet10. For the push rod27to move stably, one or more guide ribs257are equipped in any one of the housing250and the push rod27, and one or more guide grooves273and274which receive the one or more guide ribs257may be equipped in the other one thereof. In this case, the one or more ribs257and the one or more guide grooves273and274may be formed into a curved shape. Or the one or more ribs257may be formed in a circular or rectangular shape and the one or more guide grooves273and274may be formed in a curved shape. As an example,FIG.46shows that the one or more guide ribs257are equipped in the housing250and the one or more guide grooves273and274are equipped in the push rod27. Although not limited, each of the guide grooves273and274may be equipped in a first surface (upper surface based on the drawing) of the push rod27and a second surface (lower surface based on the drawing) which faces the first surface, and the guide projection257may be equipped in each of the first housing251and the second housing252. The guide grooves273and274may be formed in arc shape. At this time, the guide grooves273and274may be arranged to be convex in a direction away from the hinge shaft4010. And the center of the arc of the guide grooves273and274may be the hinge shaft4010. Meanwhile, the push rod27may be placed adjacent to the hinge shaft4010. When the push rod27is placed more adjacent to the hinge shaft4010, the door opening device25is simplified and compact, and the length of the push rod may be reduced. The hinge shaft4010may be placed on an upper surface of the first refrigerating compartment door201. The first refrigerating compartment door201may include a first side201aand a second side201bfacing the first side201a, and the hinge shaft4010may be placed adjacent to the first side201a. That is, based on an imaginary line L, which divides a space between the first side201aand the second side201bin half, the hinge shaft4010may be placed in an area corresponding to an area between the imaginary line L and the first side201a. And the push rod27may be placed between the motor261and the hinge shaft4010. In addition, the push rod27may be placed in the area corresponding to an area between the imaginary line L and the first side201a. At this time, the push rod27may be placed between the imaginary line L and the hinge shaft4010. Therefore, according to the present disclosure, as the push rod27is placed adjacent to the hinge shaft4010, an opening angle of the first refrigerating compartment door201may be increased by using a short length push rod27. The door opening device25may further include a position sensing unit for detecting a position of the push rod27. The position sensing unit may include a first position sensor281and a second position sensor282. As an example, the first position sensor281and the second position sensor282may be arranged in the housing250. And a magnet275may be equipped in the push rod27. The first position sensor281and the second position sensor282may be a magnetic sensor for detecting the magnetism of the magnet275. In the present disclosure, a position of the push rod27when the first position sensor281detects the magnet275or a position of the push rod27when the first position sensor281faces the magnet275may be an initial position. A position of the push rod27when the second position sensor282detects the magnet275or a position of the push rod27when the second position sensor282faces the magnet275may be a last position. A control unit may control the motor261based on the information sensed at each position sensors281and282. In the present implementation, while the push rod27moves to the last position from the initial position, the first refrigerating compartment door201may be opened. In the present disclosure, opening a “door” means that a storage space which is opened and closed by the door is in communication with an outside of the refrigerator. As another example, the first position sensor281and the second position sensor282may be a light sensor. A groove or a projection unit may be equipped in the push rod27and each of the position sensors281and282may detect a groove or a projection unit. The push rod27may further include a contact end unit277which may contact a front surface (can be the front surface of a hinge assembly) of the cabinet10. The contact end unit277may be formed of a rubber material for preventing the damage to the front surface of the cabinet10by the contact with the push rod27. Meanwhile, an opening143which the push rod27penetrates, may be equipped in the frame141installed on the first refrigerating compartment door201. In the present implementation, since the push rod27do the relatively curved motion about the first refrigerating compartment door201, in order to prevent the push rod27from interfering with the frame141, an area of the opening143may be larger than a vertical cross sectional area of the push rod27. Hereinafter, an opening process of the door of the refrigerator will be described. While the first refrigerating compartment door201closes the refrigerating compartment12, the push rod27may be placed on the initial position. The first position sensor281detects the magnet275of the push rod27in the initial position. While the push rod is placed in the initial position, the contact end unit277of the push rod27may be in contact with the front surface of the cabinet10or may be spaced apart from the front surface of the cabinet10. When a door opening signal is determined to be inputted, the control unit controls the motor261to be rotated in one direction. When the motor261is rotated in one direction, the plurality of gears262,263,264,265and266are rotated in the forward direction, and the push rod27may do a curved motion about the first refrigerating compartment door201. At this time, if the contact end unit277of the push rod27is spaced apart from the front surface of the cabinet10while the push rod27is placed in the initial position, the push rod27may be rotated in a direction (counter-clockwise in the figure) in which the first refrigerating compartment door201is opened if the push rod27is in contact with the front surface of the cabinet10after the push rod27moves toward the front surface of a cabinet10while the first refrigerating compartment door201is stopped. On the other hand, if the contact end unit277of the push rod27is in contact with the front surface of the cabinet10while the push rod27is placed in the initial position, the push rod27may be rotated directly in a direction in which the first refrigerating compartment door201is opened, by the curved movement of the push rod27. While the motor261is rotated in one direction, the control unit may determine whether the push rod27reaches the last position. That is, if the motor261is rotated in one direction while the push rod27is placed in the initial position, the push rod27do a curved motion and in this process, the magnet275of the push rod27is undetected in the first position sensor281. And if the magnet275of the push rod27is detected in the second position sensor282during the curved motion process of the push rod27, the control unit may determine that the push rod27reaches the last position. When the push rod27is determined to reach the last position, the control unit may stop the motor261. Specifically, as shown in (a) ofFIG.50, while the push rod27is placed in the initial position, if the motor261is rotated in one direction, the push rod27attempts to move toward the front surface of the cabinet10while doing a curved motion. When the push rod27contacts the front surface of the cabinet10, the push rod27pushes the front surface of the cabinet10and a rotation force acts on the first refrigerating compartment door201by a reaction by force of the push rod27pushing the front surface of the cabinet10, and the first refrigerating compartment door201may be rotated in the counter-clockwise direction on the drawing about the hinge shaft4010as the center. Accordingly, the first refrigerating compartment door201may be automatically opened. At this time, as a moving distance of the push rod27is increased, like (b) and (c) ofFIG.50, a rotation angle of the first refrigerating compartment door201is increased. In the present implementation, the moving distance of the push rod27means a protrusion length of the push rod27when the push rod27actually protrudes from the first refrigerating compartment door201. Also, like (d) ofFIG.50, when the push rod27reaches the last position, the motor261may be stopped. At this time, in the present implementation, the rack gear272of the push rod27is formed in a curved shape, and as a center of the curve becomes a hinge shaft, while maintaining a state in which the contact end unit277of the push rod27is in contact with a portion of the front surface of the cabinet10, the protrusion length of the push rod27is increased and the rotation angle of the first refrigerating compartment door201is increased by a rotation of the first refrigerating compartment door201. As the first refrigerating compartment door201is opened while the push rod27maintains to be in contact with a portion of the front surface of the cabinet10, damage or noise of the cabinet10by the slip of the push rod27may be prevented. If the push rod27has a linearly shaped rack gear, when the first refrigerating compartment door201is opened, it may be easily assumed that a slip phenomenon in which the contact end unit of the push rod27moves to a left on the drawing from a point of the front surface of the cabinet10may occur. As the rack gear272of the push rod27is formed in a curved shape, while the push rod27reaches the last position, an imaginary line which connects a point engaged with the last gear of the plurality of gears262,263,264,265and266at the rack gear272to the contact end unit277of the push rod27, may be perpendicular to the front surface of the cabinet10. In this situation, even if the external force acts on the first refrigerating compartment door201in the direction in which the first refrigerating compartment door201is closed, the push rod27may move toward the initial position by a reverse directional rotation of the plurality of gears262,263,264,265and266, and in this process, since a moment does not act on the push rod27, the push rod27and the plurality of gears262,263,264,265and266may be prevented from being damaged. If, when the push rod27has a linearly shaped rack gear, while the push rod27reaches the last position, an imaginary line which connects a point engaged with the last gear of the plurality of gears at the rack gear272to the contact end unit277of the push rod27, may be inclined to an angle less than 90 degrees with the front surface of the cabinet10. In this case, if the external force acts on the first refrigerating compartment door201in the direction in which the first refrigerating compartment door201is closed, since the moment acts on the push rod27, the push rod27and the plurality of gears262,263,264,265and266are likely to be damaged. Also, as the rack gear272of the push rod27is formed in a curved shape, an opening angle of the door may be increased compared with when the rack gear272of the push rod27is formed in a linear shape. Also, when trying to open the door by a fixed angle, a length of the push rod when the push rod has a curve-shaped rack gear may be shorter than a length of the push rod when the push rod has a linear-shaped rack gear. Accordingly, a door opening device may be compact and when the door opening device is compact, even if a thickness of the door is decreased, there is an advantage to install a door opening device for automatic opening of a door. On the other hand, as shown in (d) ofFIG.50, while the push rod27reaches the last position, at least a portion of a rear surface201cof the first refrigerating compartment door201may be placed forward than a front surface202aof the second refrigerating compartment door202, and accordingly, a gap G of a certain distance may be formed between a one end unit of the rear surface201cof the first refrigerating compartment door201and a one end unit of the front surface202aof the second refrigerating compartment door202. When the user's hands are not available, the gap G may be set enough to allow the user's elbow or foot to be inserted. Accordingly, while the first refrigerating compartment door201is rotated by a certain angle, by inserting the elbow or foot in the gap G, the opening angle of the first refrigerating compartment door201may be manually increased. On the other hand, while the push rod27reaches the last position, the control unit may determine whether a time when the push rod27reaches the last position passes a certain amount of time or not. If the time when the push rod27reaches the last position passes the certain amount of time, the control unit may control the motor to be rotated in the other direction for the push rod27to return to the initial position. While the motor261is rotated in the other direction, the control unit may determine whether the push rod27reaches the initial position or not. When the push rod27is determined to reach the initial position, the control unit may stop the motor261. FIG.51is a view illustrating a push rod according to a second implementation,FIG.52is a view illustrating a state of the push rod ofFIG.51placed in an initial position,FIG.53is a view illustrating a state of the push rod ofFIG.51protruding from a frame of a first refrigerating compartment door, andFIG.54is a view illustrating an opening process of a refrigerator door according to the second implementation. While the present implementation is the same as the first implementation, there is a difference in the form of a push rod. Therefore, hereinafter, only characteristic parts of the present implementation will be described. With reference toFIGS.51to54, a push rod47of the present implementation may include a body unit470in which a curve-shaped rack gear472is equipped and an extension unit471provided on one side of the body unit470. The push rod47may pass through the opening143in a Y-axis direction or inclined direction to an X-axis from the Y-axis. The extension unit471may include a contact end unit477for contacting the front surface of the cabinet (Referring11ofFIG.44). A maximum width W2of the extension unit471in a first direction (X-axis direction inFIG.51) which is intersected with a direction in which the push rod47passes through the opening143may be equal to or smaller than a width W1of the opening143in the first direction. Accordingly, a foreign substance may be minimally introduced into the opening143by the extension unit471. Or, when the contact end unit477is provided in the extension unit471, a maximum width of the contact end unit477in the first direction may be the same as the width W1of the opening143in the first direction. Therefore, as shown inFIG.52, when seeing the contact end unit477, only the contact end unit477or only the extension unit471and the contact end unit477may be shown from the opening143. InFIG.52, the push rod47is placed in the initial position and in this state, since an inner space of the frame141is not shown by the extension unit471, an esthetic sense is improved, and a foreign substance may be minimally introduced through the opening143. The maximum width W2of the extension unit471in the first direction may be equal to or greater than a width W3of the body unit470in the first direction. When the maximum width W2of the extension unit471in the first direction is greater than the width W3of the body unit470in the first direction, a width of a connected portion with the body unit470in the extension unit471in the first direction may be formed smaller than a width of the contact end unit477in the first direction in the extension unit471. This is for preventing an interference between the push rod47and the frame141while the push rod47does a curved motion about the first refrigerating compartment door201. At this time, the farther away from the contact end unit477, in other words, the closer to the side of the body unit470, a width of at least a portion of the extension unit471in the first direction may become smaller. If the width W2of the extension unit471in the first direction is the same as the width W3of the body unit470in the first direction, a groove for preventing an interference with the frame141may be formed in the extension unit471during the movement process of the push rod47. A contact area of the contact end unit477of the push rod47and the cabinet10according to the present implementation may be larger than a contact area of the contact end unit277of the push rod27and the cabinet10of the first implementation. Therefore, according to the present implementation, even if an external force acts on the first refrigerating compartment door201before the push rod47returns to the initial position in a state of reaching the last position, a damage of a contacted point with the contact end unit477of the push rod47may be minimized in the cabinet10. Although the above implementations described that the door opening device is equipped in the refrigerator door, in contrast, it is also possible that the door opening device is equipped in the cabinet. Also in this case, the push rod may include a push rod which has the curve-shaped rack gear described above, and the push rod may be placed adjacent to the hinge shaft. Also the buffer unit of the door opening device may be coupled to the installation unit equipped in the cabinet. In the control method of the refrigerator1according to the proposed implementation, the following effects may be expected. In the refrigerator according to the implementation of the present disclosure, even when the user is holding the object in both hands, the door opening device is driven through detection of the sensing assembly provided at the door, and the door is automatically opened, and thus user convenience can be enhanced. And the door opening device enables the door to be opened, such that at least a user's body, e.g., the elbow is put therein, and opens the door, and thus the user can put a part of his/her body in the open gap, and can easily further open the door. Therefore, since the user can completely open the door without use of both hands, the user convenience can be further enhanced. In particular, when one pair of doors are disposed in parallel, a distance between the rear surface of the automatically opened door and the front surface of the closed door can be sufficiently provided, and thus the additional opening can be easily performed. Although a few implementations of the present disclosure have been shown and described, it would be appreciated by those skilled in the art that changes may be made in these implementations without departing from the principles and spirit of the disclosure, the scope of which is defined in the claims and their equivalents. INDUSTRIAL APPLICABILITY According to embodiments, use convenience is improved, thereby achieving high industrial applicability. | 134,122 |
11859430 | BRIEF SUMMARY OF THE INVENTION The present invention is a heavy duty full energy, encoder driven non-handed electric door operator. The present invention includes a motor having an internal encoder, a controller, and a single solid drive gear. More particularly, the present invention is a heavy duty full energy, encoder driven non-handed electric door operator comprising: a motor having a first end and a second end and an encoder configured to receive an external set of predetermined instructions; a motor mounting bracket connected to said motor at said second end of said motor; a multi-layer housing connected to said motor mounting bracket, said multi-layer housing further comprising a front housing plate, a middle housing plate and a back housing plate; a housing mounting bracket connected to said multi-layer housing; a controller in electronic communications with said motor, said controller for transmitting said external set of predetermined instructions to said encoder of said motor; a first transfer shaft assembly in connection with said motor, said first transfer shaft assembly having a first transfer gear and a first transfer shaft; a second transfer shaft assembly having a second transfer gear and a second transfer shaft, said second transfer shaft assembly in connection with said first transfer shaft assembly; a third transfer shaft assembly having a third transfer gear and a third transfer shaft, said third transfer shaft assembly in connection with said second transfer shaft assembly; an output shaft and output gear in connection with said third transfer shaft assembly, said output shaft having a first end and a second end wherein each of said first end of said output shaft and said second end of said output shaft terminates in a nondetachable spline; and a mounting plate detachably connected to said motor mounting bracket and said multi-layer housing; said heavy duty full energy, encoder driven non-handed electric door operator for operating heavy swing doors external to a building, said heavy swing doors required to be open or remain open in strong wind conditions. The encoder driven non-handed door operator of the present invention results in fewer components and renders the present invention a robust, reliable, user-friendly, cost-efficient, programmable, and accurate device. Further, the present invention is effective for use in larger, heavier swings doors such as ones found in hospitals and other larger buildings where the swing doors may are external to the building and must open or remain open, especially even in strong wind conditions. A housing contains the components of the present invention. The housing is die cast which insures exact fit, faster assembly and closer gear tolerances. A spring adjusting bolt has three tension adjustments, facilitating pre-tensioning of the spring. The encoder driven non-handed electric door operator of the present invention may either be low or high energy, depending on the swing door used. For purposes of this application, the present invention discussed is for use as a low energy operator. The present invention is a heavy duty door operator used at the exterior of a building and withstands strong wind loads. The door operator of the present invention is used for large doors, such as hospitals. DETAILED DESCRIPTION OF THE INVENTION The heavy duty full energy, encoder driven non-handed electric door operator of the present invention includes a motor having an internal encoder, a controller, an internal spring, and a single solid drive gear resulting in fewer components and rendering the present invention a more robust, reliable, user-friendly, cost-efficient, programmable, and accurate device than its predecessor. The heavy duty low or full energy, non-handed swing door operator is configurable to accommodate right hand and left hand pull as well as right hand and left hand pull. In other words, one heavy duty low or full energy, non-handed swing door operator replaces four (4) prior art “handed” (e.g., fixed as either a LH unit, LHR unit, RH unit, or RHR unit) swing door operators. The present invention has one spline extending distally from the gear box on one side, and a separate spline on the opposite side also extending distally from the gear box (a “double spline” configuration). The splines are solid steel reducing the event of shearing off that is inherent in the bolt on splines. This solid spline is less likely to break off because the spline is not hollowed out but rather consists now of solid steel. The solid steel is an integral part of the last drive gear in the box. The present invention is die cast. The present invention further eliminates the use of cams. Instead, the present invention replaces the cams with an intelligent encoder (e.g., to count the revolutions). More particularly, the motor of the present invention has an internal encoder that counts revolutions and calculates the amount that the cams were doing, but does so automatically and in real-time. A controller connected to the motor may be pre-programmed with a set of instructions to operate the door operator as desired (e.g., how far the door should swing open before it stops? When the door should stop? How long the door is to be held in an open position? How fast the door should swing open? How fast the door should swing closed?). The encoder motor reduces or eliminates the need for a large wiring harness. The controller is in communication with the encoder. The controller is programmed with a set of instructions (e.g., time to open, the rate that the door is opening, when during the opening phase the door slows down, at what time after opening begins is the door stopped, at what time does the door begin to close, the rate of closure and the time for the door to become fully closed). There are several other types of instructions, including, but not limited to whether the user could open the door by just pushing the door and having the door being held opened after the door opens. The present invention may include any number of sensors or inputs used to actuate the door operator and open the swing door. These sensors include a mat that detects when weight is being placed thereon (the mat being in front of the door), such mat having motion sensors that sense when someone is approaching the door. However, the sensor will not work if another sensor on the opposite side of the door detects that there is someone on the other side of the swing door. Other types of sensors or inputs to open the swing door include a touch pad button and simply just pushing the swing door open. A number of redundancies may be included for safety measures. These redundancies include, but are not limited to, increasing the number of laser beams used by the motion detectors to detect individuals the closer they get to the door to avoid the door from closing on them. There will be, however, a balance to be made, as increasing the number of laser beams also significantly increases the costs necessary to incorporate those additional safety features. The plate used to mount the door operator of the present invention is a reversible mounting plate such that it can be used in four different configurations and also retrofitted to other branded door operators. The single mounting plate has rubber mounts thereon at each corner. The mounting plate is removable to use on the opposite side of a gear box. This is done via removal and replacement of a plurality of fasteners. The present invention uses six (6) screws, though other amounts and types of fasteners (e.g., rivets, bolts, etc. . . . ) may be used and still be within the contemplation of the present invention. This process of removing the mounting plate to use on the opposite side of a gear box provides for the universal or non-handedness of the present invention. It is the only mechanical change needed to change configurations. The plate will only bolt or securely attach on one way. An internal clock spring eliminates the separate need for a spring retainer. Moreover, use of an internal clock facilitates the installation process. Assembly is easier because the gear boxes are all assembled the exact same way. Referring now toFIG.1, heavy duty door operator or gear box is comprised of motor12attached to motor mounting bracket14at end13. Motor mounting bracket14, in turn, is removably attached to multi-layered housing16via fasteners28. The present invention uses socket head cap screws. However, other comparable and robust fasteners may be used and still be within the contemplation of the present invention. Housing mounting bracket18then removably attaches to multi-layered housing16at end19. Bottom mounting plate20serves as a base. Bottom mounting plate20is reversible such that regardless of the configuration of the that is using the present invention is used on, the present invention will retrofit the door simply by attaching bottom mounting plate20to the top of heavy duty door operator or gear box10. Rubber mounts50and52(only two are shown inFIG.1) traverse the corners of bottom mounting plate20via apertures58and60, as shown inFIG.1. Still referring toFIG.1, front housing plate32of multi-layered housing16is shown attached via a plurality of fasteners (38,40,42,44,46,48). Spline36of output shaft (not shown) traverses aperture34of front housing plate32. An arm (not shown) connects to spline36at one end and to the door at the other end upon which the present invention is attached. Motor12terminates in electrical wiring24and26within lip23and protected via cap22, as shown inFIG.1. Referring now toFIG.2, the back side of the present invention is shown. Reversible bottom mounting plate20contains rubber mounts54and56which traverse apertures62and64, respectively, of reversible bottom mounting plate20. Fasteners78and80secure motor12to motor mounting bracket14at end13. Multi-layered housing16connects to motor mounting bracket14at one end and to housing mounting bracket18at the other end. Back housing plate (or member)74is shown having spline70extending therefrom via aperature72. A plurality of fasteners (84,86,88,90) secure back housing plate74to multi-layered housing16. Still referring toFIG.2., two stop bolt assembly66, comprised of bolt66A and nut66B attach to back housing plate74of multi-layered housing16via protruding portion69. Screw76provides support for middle housing plate112(not shown). Now turning toFIG.3, the left side of the present invention is shown. The cover of motor12is secured via screws140and142. Cap22is in a closed position (but may be opened via a hinge to access the contact points of the wiring with motor12). Cap22rests snuggly within lip23. Connection ends94,96and98connect to controller (not shown) to receive set(s) of instructions transmitted from controller to encoder (not shown). A plurality of fasteners (78,28,30,80) secures motor12to motor mounting bracket14. Splines36and70are shown extending distally from heavy duty gear box10. Front housing plate32and back housing plate74of multi-layered housing16are shown. Referring now toFIG.4, the right side of an embodiment of the present invention is shown. A plurality of fasteners (100,102,104,106) secure housing mounting bracket18to multi-layered housing16. Two stop bolt assembly66used to adjust the tension of the interior coil spring (not shown) is shown. Again, front housing plate32(and spline36extending therefrom) and back housing plate74(and spline70extending therefrom) of multi-layered housing16are shown. The rubber mounts are of a configuration that may traverse plate20then remain secured in place. For example, a more narrower in diameter upper portion108of rubber mount52traverses plate20while the more wider in diameter lower portion110cannot pass through aperture60and thus remains under bottom plate20. Now turning toFIG.5, the top view of the present invention shows the three plates of the multi-layered housing. These are front housing plate32, middle housing plate112and back housing plate74. Front housing plate32is the most narrow followed by a wider back housing plate74. Middle housing plate112is the widest of all plate layers. Turning now toFIG.6, plurality of fasteners (128,130,132) secures motor mounting bracket14to bottom mounting plate20. Similarly, plurality of fasteners (134,136,138) secures housing mounting bracket18to bottom mounting plate20. Motor mounting bracket14and housing mounting bracket18may be used in either direction as apertures (114,116,118,120,122,124) therein traverse the entire length of each bracket and thus may be secured via fasteners on either side, as shown inFIGS.7and8. Turning now toFIG.9, an exploded view depicting all of the components of the present invention is shown. Motor12connects to a first transfer shaft assembly146having first transfer gear147and first shaft149and connected to bearing144. Second transfer shaft assembly164having second gear166and second shaft168and connected to bearing156connects to first transfer shaft assembly146. Third transfer shaft assembly170having third gear172and third shaft174connects to bearing158and connects to second transfer shaft assembly164. Third transfer shaft assembly170connects to output shaft176. Output shaft176is permanently connected to (and comprised of a solid material, i.e., steel) gear198and terminating at either end as splines36and70. Each of splines36and70traverse bearings and terminate extending distally such that an arm may be connected to either side, depending on which way a swing door is desired to swing. The heavy duty low or full energy, non-handed swing door operator of the present invention provides predictability, reliability, robustness and better programmability to door operators. While the present invention is described as being electrically connected to the controller for the door operator, the present invention may also be wireless and send and receive signals via Bluetooth® or other comparable wireless technology platform. To operate the gear box, several gears and corresponding shafts work synergistically. For example, a motor spiral bevel gear turns a first spiral bevel gear. The first spiral bevel gear is attached to a first shaft. The first shaft then turns a second gear. The second gear is attached to a second shaft. The second shaft turns a third gear. The third gear is attached to a third shaft. The third shaft turns a fourth gear. The fourth gear is welded to a main shaft with splines on both sides allowing installation of the arms on either side of the present invention. The present invention has application in the medical industry, such as swing doors used in hospitals (e.g., admittance or emergency room, surgery, recovery areas). However, it is contemplated that the present invention may also have application in other areas such as hotels, restaurants, commercial buildings and warehouses, where large doors require automatic opening to, for example, allow physically impaired individuals easy access into such structures (where it may be difficult otherwise) or to allow large items to be pushed through on rollers where individuals are handling the deliverables and such encoder driven non-handed door operators facilitate passing through a single swing door or even double swing doors such as ones found in hospitals and other larger buildings where the swing doors are external to the building and must open or remain open even in strong wind conditions. Wind speeds of about 19 mph or more tend to prevent swing doors from either opening or keeping them from closing due to the amount of force the wind exerts on the swing doors. Strong wind conditions are when winds are sustained at 25 mph or higher for an extended period of time. The present invention is robust enough to overcome such forces and open, keep open and/or close swing doors in such conditions. The present invention reduces the number of components required to perform the functions of the door operator. Fewer components means fewer areas for failure of the device, and thus also translates to less inventory and reduced or eliminated repair costs—because there are less components which can fail—yielding a cost savings to the users. The various embodiments described herein may be used singularly or in conjunction with other similar devices. The present disclosure includes preferred or illustrative embodiments of specifically described apparatuses, assemblies, and systems. Alternative embodiments of such apparatuses, assemblies, and systems can be used in carrying out the invention as described herein. Other aspects and advantages of the present invention may be obtained from a study of this disclosure and the drawings. | 16,750 |
11859431 | DETAILED DESCRIPTION OF EMBODIMENTS Embodiments of the invention will now be described with reference to the accompanying drawings. The invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. The terminology used in the detailed description of the particular embodiments illustrated in the accompanying drawings is not intended to be limiting of the invention. In the drawings, like numbers refer to like elements. FIG.1is a schematic front view of a swing door-based entrance system. The entrance system1comprises a swing door member10having a door leaf12. The swing door member10is pivotally supported at a vertical edge14by hinges16for allowing opening of the swing door member10from a closed position to an open position, as well as for allowing closing of the swing door member10from the open position to the closed position. The swing door member10is hence supported by a door frame11for pivotal motion around a rotational axis18which is coincident with the hinges16. The entrance system1comprises a motorized automatic door operator30capable of causing opening of the swing door member10. A linkage (arm mechanism)40connects the automatic door operator30to the door leaf12of the swing door member10. The door operator30may be arranged in conjunction with the door frame11and is typically a concealed overhead installation in or at the door frame11(hence, the linkage mechanism40and automatic door operator30are normally not as visible to the naked eye as appears to be the case inFIG.1). The automatic door operator30may be triggered by sensor equipment in the entrance system1. Such sensor equipment may include activity sensors (e.g. IR or radar based sensors) which are adapted to detect an approaching user and accordingly trigger the automatic door operator30to open the swing door member10. Alternatively, the automatic door operator30may be triggered by a user actuating a door-open push button15, or similar actuator. The entrance system1will typically also allow the user to open or close the swing door member10by pulling or pushing a door handle13by manual force, i.e. without using the motorized automatic door operator30. The automatic door operator30may provide automatic opening of the swing door10in various possible applications. Such applications include, for instance, facilitating a disabled person's access to his or her private home, providing access through entrance ports or internal doors at healthcare buildings, office premises, industries or retail stores, providing comfort access to hotel rooms, etc. The automatic door operator30may also be used in fire door applications, as previously explained in the background section of this document. The swing door member10furthermore has a sensor unit mounted to the door leaf12. The sensor unit comprises a door angle sensor S1capable of measuring a door leaf angle α of the door leaf12. In embodiments of the invention, the door angle sensor S1comprises at least one of an accelerometer and a gyroscope. FIG.4illustrates the opening of the swing door member10in one embodiment of the entrance system1from a shut closed position18to a swung open position19. The opening movement is indicated by an arrow2. As can be seen inFIG.4, during the opening2of the swing door member10, the door leaf angle α as measured by the door angle sensor S1will span from about 0° to about 90°. In other embodiments, the swung open position may be at a door leaf angle α different from about 90°, such as for instance about 180°. FIG.5correspondingly illustrates the closing of the swing door member10of the entrance system1from the swung open position19to the shut closed position18. The closing movement is indicated by an arrow3. As can be seen inFIG.5, during the closing3of the swing door member10, the door leaf angle α as measured by the door angle sensor S1will span from about 90° to about 0°. In other embodiments where the swung open position is at a door leaf angle α different from about 90°, such as for instance about 180°, the door leaf angle α as measured by the door angle sensor S1will of course start spanning from such other door leaf angle α. The present invention makes novel and inventive use of the door angle sensor S1to automatically establish a linkage reduction curve for the linkage40in a learn mode of the automatic door operator30. This will described in more detail later in this section. To avoid dangerous situations where a present, approaching or departing person or object (including but not limited to pets or articles brought by the person) might be hit or jammed by the door leaf12of the swing door member10, a safety sensor may be provided. Hence, in some embodiments, in addition to the door angle sensor S1, the sensor unit mounted to the door leaf12comprises a safety sensor for monitoring a zone at or near the door leaf12for presence or activity of a person or object. This can be seen for sensor unit S in the entrance system1shown inFIG.2; the sensor unit S comprises the door angle sensor S1as well as a safety sensor S2. Advantageously, the sensor unit S contains both the door angle sensor S1and the safety sensor S2within a common single device housing. The sensor unit S is mounted at an appropriate position on the surface of the door leaf12. As can be seen inFIG.2, such a position is often at an uppermost part of the door leaf12. The purpose of the safety sensor S2is to monitor a zone, or volume, at or near the door leaf12for presence or activity of a person or object. If a person or object is detected in the monitored zone, the automatic door operator30shall not be allowed to move the swing door member10in a direction in which the swing door member10may hit or jam that person or object. Accordingly, the automatic door operator30is configured to receive monitoring data from the safety sensor S2. If the monitoring data indicates presence or activity of a person or object in the monitored zone, the automatic door operator30is configured to refrain from driving a motor of the automatic door operator30to cause movement of the swing door member10, and/or force the motor to stop an ongoing movement of the swing door member10. Reference is now made toFIG.3which illustrates an embodiment of the automatic door operator30in more detail. The automatic door operator30comprises a motor34, typically an electrical motor, being connected to a transmission35. An output shaft35aof the transmission35rotates upon activation of the motor34and is connected to the linkage40. The linkage40translates the motion of the output shaft35ainto an opening motion of the door leaf12with respect to the door frame11(c.f opening movement2inFIG.4). The automatic door operator30also comprises a control arrangement20including a controller31which is configured for performing different functions of the automatic door operator30. One or more of these functions relates to opening of the door leaf12with respect to the door frame11. Accordingly, the controller31has a control output31aconnected to the motor34for controlling the actuation thereof. In addition to the controller31, the control arrangement20comprises a number n of sensor functions, including or consisting of the aforementioned door angle sensor S1, safety sensor S2, activity sensor and door-open push button15. The sensor functions are operatively connected with the controller31to report detection results or measurement readings to the controller31. A revolution counter33, such as an encoder or other angular sensor, is provided at the motor34to monitor the revolution of a motor shaft of the motor34. The revolution counter33is connected to an input31bof the controller31. The controller31is configured to use one or more readings of the revolution counter33, typically a number of pulses generated as the motor shaft rotates, for determining a current angular position, e.g. door leaf angle α, of the door leaf12of the swing door member10. The controller31may be implemented in any known controller technology, including but not limited to microcontroller, processor (e.g. PLC, CPU, DSP), FPGA, ASIC or any other suitable digital and/or analog circuitry capable of performing the intended functionality. The controller31has an associated memory32. The memory32may be implemented in any known memory technology, including but not limited to E(E)PROM, S(D)RAM or flash memory. In some embodiments, the memory32may be integrated with or internal to the controller31. As seen at32a, the memory32may store program instructions for execution by the controller31, as well as temporary and permanent data used by the controller31. The embodiment of the automatic door operator30shown inFIG.3is intended for fire door usage and therefore includes a forced close arrangement36. (It is to be noticed that while the present invention is believed to be advantageous in fire door applications, the invention may alternatively be used in applications which do not relate to fire door usage.) The forced close arrangement36is adapted to provide mechanical energy via a transfer mechanism to the linkage40, so as to cause forced closing of the door leaf12with respect to the door frame10in the event of a fire alarm. In the disclosed embodiment, the forced close arrangement36comprises a helical compression spring. During opening of the swing door member10by the torque generated by the motor34, the compression spring is tensioned by the rotation of the output shaft35a, as can be seen at36a. During the forced closing cycle, the accumulated spring force of the compression spring is transferred to the output shaft35at36aby means of the transfer mechanism, which in the disclosed embodiment includes a pressure roller that acts on a cam curve being connected to the output shaft35a. In other embodiments, the forced close arrangement36may comprise a different kind of spring, and its transfer mechanism may comprise a different kind of mechanism. The controller31may receive an external fire alarm signal via a control input and generate a control signal31cto the forced close arrangement36, so as to cause release of the accumulated spring force. As will now be described with reference toFIGS.6and7, the automatic door operator30is operable in a learn mode60and in an operational mode70. In the learn mode60, the controller31of the automatic door operator30is configured to establish information required as control input data for subsequent use by the controller31during normal operation. The established information may include the inertia62of the swing door member10(being a constant value), the friction63in the transmission (gear box) of the electric motor34(being linearly dependent on the door leaf angle), and—when a forced close arrangement36is provided—the spring force64thereof (being linearly dependent on the door leaf angle). In addition to the above, in the learn mode60the controller31of the automatic door operator30is configured to automatically establish a linkage reduction curve65by determining, for a movement of the swing door member10between the shut closed position18and the swung open position19of the door leaf12, the torque required by the motor34to cause movement of the door leaf12at different door leaf angles α. The different door leaf angles are determined from measurement readings of the door angle sensor S1. The torque may be determined by counting the number of pulses reported from the revolution counter33during movement of the swing door member10by a certain angular amount, i.e. an increase in the door leaf angle α by a certain angular amount m. The certain angular amount m may, for instance, be 1°, or more or less than 1° depending on the desired angular resolution of the linkage reduction curve65to be established. A first example of a linkage reduction curve65′ is shown inFIG.8. The linkage reduction curve65′ inFIG.8has been automatically established as described above for a configuration of a swing door member10mounted for pull actuation by the automatic door operator30. A second example of a linkage reduction curve65″ is shown inFIG.9. The linkage reduction curve65″ inFIG.9has been automatically established as described above for a configuration of a swing door member mounted for push actuation by the automatic door operator. The automatically established linkage reduction curve65(65′,65″) may be stored in the memory32for subsequent usage by the controller31in the operational mode70. In the operational mode70, the controller31of the automatic door operator30is configured to compensate for a non-linear torque transfer characteristic of the linkage40by applying the established linkage reduction curve65when controlling the motor34to cause the door member10to swing open. The controller31will also use the other control input data established in the learn mode60, e.g. the inertia62, friction63and spring force64, as well as the number of pulses reported from the revolution counter33during movement of the swing door member10, to repeatedly calculate set values of the drive current of the motor34from this information during the movement of the door member10to cause it to swing open. In some embodiments, the controller31may use measurement readings from the door angle sensor S1also in the operational mode70, to improve the angular accuracy of the control of the movement of the swing door member10. The reader is invited to notice the considerable difference between the linkage reduction curves65′ and65″ inFIGS.8and9. The present invention offers a substantial improvement since it offers precise and automatic recognition of the linkage reduction curve65of the linkage40, thereby making it possible to accurately compensate for the non-linear torque transfer characteristic of the linkage40—which may differ considerably from installation to installation, as evidenced byFIGS.8and9. The functionality performed in accordance with the present invention as described herein is illustrated as a method100in the flowchart diagram shown inFIG.10. The method100first involves operating110the automatic door operator30in the learn mode60. The learn mode60involves controlling120the motor34to cause movement of the door leaf12between the shut closed position18and the swung open position19of the door leaf12. The learn mode60further involves obtaining130measurement readings of the door angle sensor S1during this movement, and determining140different door leaf angles α from the obtained measurement readings. The learn mode60automatically establishes150a linkage reduction curve65by determining the torque required by the motor34to cause the movement of the door leaf12at the different door leaf angles α. The method100inFIG.10then involves operating160the automatic door operator30in the operational mode70. The operational mode70involves controlling170the motor34to cause movement of the door leaf12to swing open while applying the linkage reduction curve65to compensate for the non-linear torque transfer characteristic of the linkage40. In a refined embodiment, the method100involves analyzing the established linkage reduction curve65, detecting an anomaly thereof, and causing an action in response to the detected anomaly. The anomaly of the established linkage reduction curve65may be detected by comparing the established linkage reduction curve65to predetermined reference data which may include one or more of the following information:Permitted maximum gear ratio (global maximum)Permitted minimum gear ratio (global minimum)Permitted maximum gear ratio for a given range of the door leaf angle (local maximum)Permitted minimum gear ratio for a given range of the door leaf angle (local minimum)Permitted maximum increase in gear ratio (global maximum)Permitted maximum decrease in gear ratio (global negative maximum)Permitted maximum increase in gear ratio for a given range of the door leaf angle (local maximum)Permitted maximum decrease in gear ratio for a given range of the door leaf angle (local negative maximum) The action caused in response to the detected anomaly may involve generating an audible, visible or tactile alert to inform a human user of the detected anomaly. Alternatively or additionally, the action caused in response to the detected anomaly may involve preventing operation of the motor34of the automatic door operator30. The controller31of the automatic door operator30in the entrance system1may be configured to perform the aforementioned functionality for analyzing the established linkage reduction curve65, detecting an anomaly thereof, and causing an action in response to the detected anomaly. The invention has been described above in detail with reference to embodiments thereof. However, as is readily understood by those skilled in the art, other embodiments are equally possible within the scope of the present invention, as defined by the appended claims. It is recalled that the invention may generally be applied in or to an entrance system having one or more movable door member not limited to any specific type. The or each such door member may, for instance, be a swing door member, a revolving door member, a sliding door member, an overhead sectional door member, a horizontal folding door member or a pull-up (vertical lifting) door member. | 17,525 |
11859432 | DETAILED DESCRIPTION OF THE DRAWINGS As explained at the beginning, the present disclosure deals with increasing the reliability and the convenience of an automatic closing operation of a flap and/or door in an efficient way. In this connection,FIG.1ashows a block diagram of an exemplary door/flap arrangement100. The arrangement100can, for example, correspond to a side door of a vehicle or a tailgate of a vehicle. The aspects described in connection with an arrangement100thus apply both to a door and to a flap of a vehicle. In the following text, a flap of a vehicle will specifically be discussed. The aspects described apply correspondingly to a door, so that the term “flap” can be replaced by the term “door”. The arrangement100comprises a frame or a cutout120and a flap110arranged in the frame or cutout120. The flap110is movably fixed to the frame or cutout120via hinges102. A seal126can be arranged in the frame or cutout120in order to seal off the interspace between the flap110and the frame or cutout120when the flap110is in the closed state. Furthermore, a lock125, with which the flap110can be closed and optionally locked, is arranged in the frame or cutout120. The flap110can be closed via a pre-latch and a main latch. The flap110can have a handle111, which makes it possible for a user to open the flap110. In particular, a user can operate a pushbutton, a knob and/or an operating point on the handle111in order to release the lock125so that the flap110can be opened. Furthermore, the flap110can have one or more actuators103,104(e.g. one or more electromechanical drives), which are set up to open and to close the flap110automatically. Furthermore, one or more actuators (not illustrated) can be provided in order to open and to close the lock125. These one or more actuators can be integrated in the lock125(e.g. in the form of an integrated electric motor). FIG.1bshows an exemplary lock125in a section along the gap between cutout120and flap110. The flap110typically has a bolt114, which can be clamped or latched in the lock125by a retainer or a catch122in order to close and optionally to lock the flap110. To close the flap110, the flap110can be moved toward the cutout120by the one or more actuators103, so that the bolt114is moved completely behind the retainer122by the kinetic energy of the flap110. The arrangement100typically has two different locking or latching stages, a first locking stage (also designated as a pre-latching position), in which the flap110is held in the lock125but there continues to be a gap between flap110and cutout120, and a second locking stage (also designated as the main latching position), in which the flap110is held without any substantial gap in the cutout120(and is thus in a completely closed state). Furthermore, in the completely closed state of the flap110(i.e. when the bolt114is in the main latching position), the lock125can be locked with a vehicle key or automatically. The locked state can be a logical state in which energization of the lock125is at least partly suppressed (e.g. in reaction to one or more operating triggers). Unlocking can then lead to the lock125being energized and activated again in reaction to one or more operating triggers. The arrangement100can have an automatic closing device123, with which the flap110can be pulled automatically from the first locking stage (i.e. from the pre-latching position) into the second locking stage (i.e. into the main latching position). By using a sensor121, it is possible to detect that the flap110is intended to be closed. For example, by using the sensor data from a sensor121, it is possible to detect that the gap between the flap110and the cutout120is smaller than or equal to a specific gap threshold value. This can be detected, for example, by using one or more microswitches for the detection of the pre-latching position and/or for the detection of the main latching position. Alternatively or additionally, it is possible to detect that the flap110is in the first locking stage. The sensor121can comprise a Hall sensor with which, for example, it is possible to detect that the bolt114of the flap110is in the (immediate) vicinity of the retainer122and/or in the pre-latching position of the lock125. The closing device123can be set up to transport the flap110into the lock125, in particular to pull it into the lock125, as a function of the sensor data from the sensor121. For example, the closing device123can comprise an electric motor and a suitable mechanism with which the bolt114of the door110can be transported behind the retainer122of the door lock125and/or into the main latching position. Thus, complete closure of the flap110can be effected in a convenient way. The flap arrangement100fromFIGS.1a,1bcomprises a control unit101. The control unit101(which, if necessary, can be distributed over multiple control devices) is set up to receive a control signal (e.g. from a vehicle key of the vehicle) which indicates that the flap110is to be closed automatically. Thereupon, the one or more actuators103can be caused to close the flap110automatically. Starting from an initial position201, the flap110is moved via an intermediate position202into the pre-latching position203(seeFIG.2). In the pre-latching position203, the flap110is closed but the lock125is in the first locking stage. The automatic closing operation effected by the one or more actuators103can be viewed as completed when the flap110is in the pre-latching position203. The flap110can then be transported by a closing device123into the main latching position204, so that the lock125is in the second locking stage. The one or more actuators103for the automatic closing operation of the flap110can be activated by the control unit101in such a way that, during the movement from the initial position201into the pre-latching position203, the flap110has a predefined, fixed closing speed. The profile of the closing speed of the flap110can be fixedly predefined (as a closing profile). The pre-definition of the closing speed can be the same for all the vehicles of a vehicle type and, for example, predefined during the production of a vehicle. The closing speed should be as low as possible in order to effect safe, convenient and high-quality closing of the flap110. On the other hand, the closing speed should be sufficiently high to ensure reliable latching in the pre-latching stage of the lock125. This means that the closing speed should be sufficiently high to overcome the resistance of a pre-latching mechanism of the lock125and/or in particular the resistance of a seal126. Tolerances in the seal126of a flap110(e.g. tolerances in the Shore hardness of the seal, tolerances in the wall thickness and the geometry and/or the aging of the seal, etc.) and tolerances during the construction of a flap arrangement100(e.g. tolerances in relation to the sealing gap dimension) can have an influence on the required minimum closing speed. In particular, this can result in differences in the resistance of the pre-latching mechanism and/or in the pre-latching position. Typically, tolerances of this type cannot be taken into account adequately when establishing a fixedly predefined closing speed. Furthermore, during the operating period of a flap arrangement100, changes in the properties of the seal and/or the flap geometry can result, which cannot be taken into account at the time at which a fixedly predefined closing speed is established. A fixedly predefined closing speed can lead to malfunctions in the closure of a flap110in the event of tolerance limits of the seal and/or flap adjustment and with increasing operating time. For example, it is possible for a “reversal” of an automatic flap110to occur, in which a closure of the flap110into the pre-latching stage is prevented if the fixedly predefined closing speed is too low (e.g. following a relatively long open state duration). On the other hand, too high a fixedly predefined closing speed can lead to the closure of a flap110being carried out with unnecessarily high energy and with correspondingly high closing noises. An unsuitably set closing speed can thus reduce the reliability and/or the convenience of an automatic flap110. In this disclosure, a method and a control unit are described which make it possible to adapt the closing speed of a flap110in an efficient and precise way in order to increase the reliability and the convenience of an automatically closing flap110. The resistance effected by a seal126typically decreases with increasing operating time of the seal126. The control unit101can be set up to determine usage information in relation to the operating time of the seal126of the flap arrangement100. The usage information can, for example, comprise or indicate the duration of use of the seal126and/or the number of closing operations of the flap arrangement100. The closing speed of the flap110can then be adapted as a function of the usage information, in particular reduced. For example, the closing speed can be reduced by means of an offset, wherein the offset rises as the operating time of the seal126increases. Alternatively, the closing speed of the flap110in a starting phase of the usage can be loaded or increased with a (positive) offset, wherein the offset is reduced as the operating time of the seal126increases. Thus, it is efficiently possible to reach the situation in which an automatic flap110closes reliably even following “setting” of the seal126of the flap arrangement100(and is not transported directly into the main latching position204on account of an excessively high closing speed, and causes relatively high closing noises in the process). In order to ensure safe closure of a flap110on a new vehicle, a profile of the closing speed can thus be provided with a specific offset (in particular increased), so that increased closing speeds are effected for the new vehicle. It is then possible, for example, for a percentage increase in the overall closing profile or a selective increase in an end phase of the closing profile (before the pre-latching position203is reached) to be carried out. The closing profile can be adapted in order to produce more harmonious flap running and/or a pleasant sound. The offset can then be reduced (smoothly or in many stages) over time from the new vehicle profile as far as a permanent profile. The offset can depend on expected setting losses of the seal126. FIG.4shows exemplary closing profiles405,406, wherein the closing profile406is used in the event of a new seal126and is gradually reduced to the closing profile405by reducing the offset403. The closing profiles405,406indicate the course of the closing speed401as a function of the time402or as a function of the flap/door angle. The closing profiles405,406have a starting phase (at the start of the closing operation) and a run-out phase (at the end of the closing operation). If necessary, the offset407can be applied only to the run-out phase (i.e. in the phase in which the flap110comes into contact with the seal126). During the maintenance, a check can be madeas to whether the seal126has been changed, and thus the initial closing profile406should be used again; and/oras to whether the seal126has a permanently elevated closing resistance, and thus an increased closing profile406should thus be used permanently. In particular, a permanent offset403,407can be established; and/oras to whether a specific closing profile406is to be used (e.g. a closing profile406preferred by a user of the vehicle). The seal126of a flap arrangement100typically expands and relaxes when the flap110is open. This leads to an increase in the resistance of the seal126. In the process, the resistance of the seal126increases as the duration of the relaxation rises. The control unit101can be set up to determine time information in relation to the duration of the relaxation of the seal126of the flap arrangement100. In particular, it is possible to determine how long the flap110was in the open and/or the unclosed state. The closing speed401can then be adapted as a function of the time information. In particular, the closing speed401can be increased as the duration of the relaxation of the seal126rises. FIG.5shows an exemplary relationship501between an offset502and the duration503of the relaxation (or the time period during which a flap110was in the open state). Alternatively, the reference symbol502can indicate the resistance and/or the sealing force of a seal126, from which the required offset for adapting the closing speed401or the closing profile405,406can then be determined. The relationship501can thus indicate a force/time relationship. The relationship501can be determined experimentally in advance and stored so as to be accessible to the control unit101. The control unit101can then be set up to determine an offset502for a closing operation on the basis of the time information and on the basis of the predefined relationship501. The closing speed401or the closing profile405,406for the closing operation can then be adapted with the offset502determined, in particular increased. Thus, a reliable and convenient closing operation can be effected. FIG.6shows an exemplary relationship601between an offset502and the duration603of the use of a seal126. Alternatively, the reference symbol502can indicate the resistance and/or the sealing force of a seal126, from which the required offset for adapting the closing speed401or the closing profile405,406can then be determined. The relationship501can thus be determined to indicate a force/time relationship. The relationship601can be determined experimentally in advance and stored so as to be accessible to the control unit101. The control unit101can then be set up to determine an offset502for a closing operation on the basis of the time information and on the basis of the predefined relationship601. The closing speed401or the closing profile405,406for the closing operation can then be adapted with the offset502determined, in particular reduced. Thus, a reliable and convenient closing operation can be effected permanently over the duration of use of a seal126. FIG.3shows a flowchart of an exemplary method300for operating an automatic flap and/or door110. The method300can be carried out by the control unit101of a flap and/or door arrangement100. The flap and/or door110can be transferred automatically from an open position201,202into a closed position203,204by at least one actuator103for a closing operation, wherein the flap and/or door110presses against a seal126in the closed position203,204, so that a closing operation is influenced by the mechanical resistance of the seal126. For a closing operation of the flap and/or door110, the method300comprises the determination301of time information in relation to an open state duration502during which the flap and/or door110was in the open position201,202(uninterruptedly) before the closing operation. In other words, it is possible to determine the time duration502for which the flap and/or door110has not pressed against the seal126and compressed the seal126in the process. Alternatively or additionally, the method300comprises the determination301of time information in relation to the duration of use603of the seal126. In addition, the method300comprises the operation302of the at least one actuator103for the closing operation as a function of the time information. In particular, the closing speed401of the closing operation can be adjusted or adapted as a function of the time information, at least during one phase of the closing operation. Thus, the reliability and the convenience of a closing operation can be increased. The embodiments of the present invention are not restricted to the exemplary embodiments shown. In particular, it is to be noted that the description and the figures are intended merely to illustrate the principle of the methods, devices and systems proposed. | 15,988 |
11859433 | PARTS LIST 2—door4—sun gear6—planetary gear8—structure or ring supporting planetary gears10—cover component12—post14—structure or housing upon which sun gear is disposed16—taper17—groove18—plane within which cover components are disposed19—protrusion20—slot22—stopper24—stalk26—interior space28—edge30—central axis of ring or planetary gears32—minor ring34—axis of rotation of planetary gear36—relative rotation38—direction40—direction42—relative rotation PARTICULAR ADVANTAGES OF THE INVENTION The present door includes cover components for blocking an opening without the use of a hinge as the cover components are configured to move within a plane to come together and cooperate to form a cover to seal the opening. The same cover components are configured to be removable also within the same plane and without the use of a hinge which can often take up a significant amount of space surrounding the opening. The present door can be opened or closed more expeditiously than hinged doors. A relative rotation of two structures, one of which supports a plurality of cover components coupled to planetary gears and the other one of which supports a sun gear rotationally coupled to the planetary gears, can cause the cover components to be disposed in an open state from a closed state or disposed in a closed state from an open state with a relative rotation as little as 15 degrees. In one embodiment, a continued relative rotation can cause the cover components to be disposed in an opposite state. In one embodiment, the cover components can be disposed in one of two closed states. An image can be associated with each of the two closed states. Therefore, a desired image of the two images can be chosen and displayed simply by disposing the cover in a particular closed state. DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT The term “about” is used herein to mean approximately, roughly, around, or in the region of. When the term “about” is used in conjunction with a numerical range, it modifies that range by extending the boundaries above and below the numerical values set forth. In general, the term “about” is used herein to modify a numerical value above and below the stated value by a variance of 20 percent up or down (higher or lower). FIG.1is a top perspective view of a container having an interior space protected with a door2openable by twisting the body of the container;FIG.2is a top view thereof;FIG.3is a bottom view thereof;FIG.4is a side view thereof;FIG.5is yet another side view thereof;FIG.6is a top perspective cross-sectional view of the container shown inFIG.2along line A-A;FIG.7is a side view thereof. The body includes a structure or ring8that supports a plurality of planetary gears6and a structure14upon which a sun gear4is disposed. Disclosed herein is a door2for allowing access to an interior space26of a housing. The housing is essentially made up of the two structures8,14. One end of the housing is sealed with a cover composed of a plurality of cover components10. The door includes a sun gear4, a ring8and a plurality of planetary gears6. The sun gear4includes a rotational axis and the sun gear4is configured to be attached to the housing. The ring has a central axis30coaxially disposed with the rotational axis of the sun gear4. The plurality of planetary gears6are evenly distributed about the central axis of the ring. Each planetary gear6includes a rotational axis and each planetary gear6is rotationally coupled to the ring. The rotational axis of each planetary gear6is disposed parallel to the central axis of the ring and supported on a post12. Each of the cover components10is configured to be attached to one of the plurality of planetary gears6by way of inserting a stalk24of a cover component10into a slot20of a planetary gear6. The cross-sectional shape of each slot is preferably not circular and preferably uniquely shaped such that a stalk24can only be inserted in a slot20when disposed in a unique orientation, to ease installation. When the ring is rotated with respect to the housing, the plurality of cover components separate to allow access to the interior space26of the housing. It shall be noted that, the present cover is applied to an opening that is circular in shape and each planetary gear6is disposed at a vertex of a hexagon and the each cover component is configured in the shape of a triangle and another vertex from each hexagon will meet with another like vertex of another hexagon at the center of the hexagonally-shaped cover formed from all the cover components10. In the embodiments shown throughout herein, the shape of the cover is a hexagon and six planetary gears are used, each disposed at a vertex of the hexagon. The present concept of using cover components to form a cover to seal, is extendable to openings of other shapes, e.g., a pentagon, a square, a triangle, a septagon, an octagon or another polygon, as long as the cover components are configured to be triangles and a vertex of the triangle meets vertices of other identically-shaped triangles at the center of the polygon. Referring toFIGS.6and7, the interface at which ring8is supported by structure14is preferably slanted with a taper16and ring8is preferably retained with a groove17disposed at a bottom periphery of ring8and a matching protrusion19disposed on structure14. Other means for facilitating this interface are possible, e.g., with bearings to lessen resistance experienced in the relative rotation of structure14and the ring6. The rings disposed around each planetary gear6minor rings32need not protrude within the opening of the interior space26. However, for an application where the entrance size of the opening to the interior space26is not a concern, the minor rings32may be configured in the manner shown throughout. The minor rings32need not be configured in the manner shown throughout. However, for a container configured to be hand operated, the minor rings32help improve grasps while held in a user's hand. Further, although not shown, the planetary gears may alternatively be configured to ride on a ring gear instead of a sun gear provided that a relative movement between the two types of gear can cause synchronized movements to multiple components which drive the cover components. A ring gear is a gear having teeth disposed on the inner race of the gear. FIG.8is a top perspective view of a container of having an interior space exposed by disposing the door which covers an opening to the interior space in an orientation to just clear the opening to the interior space26; AsFIG.9is a top perspective view of a container of having an interior space exposed by disposing the door which covers an opening to the interior space in an orientation where the cover components10are fully extended from the opening;FIG.10is a side view thereof; It shall be noted that the cover components10fully clear the opening of the container and the cover components are disposed in the same plane18they are disposed in while the cover is disposed in the closed position. Referring toFIG.8, a relative rotation of the structures8,14indicated as relative rotation36will cause the planetary gears6to rotate in direction38until cover components10eventually come together with their vertices meeting along the central axis of the ring8in one of the two terminal closed states. Conversely, a relative rotation of the structures8,14indicated as relative rotation42will cause the planetary gears6to rotate in direction40until cover components10eventually come together with their vertices meet along the central axis of the ring8in the other one of the two terminal closed states. FIG.11is a top perspective view of the container ofFIG.1with a cover component10removed to reveal a portion of the interior space of the container.FIG.12is a top perspective view of the container ofFIG.1with all cover components10removed to reveal the interior space of the container.FIG.13is a top perspective view of the container ofFIG.1with the structure8supporting the planetary gears removed to reveal relationships between several planetary gears6and the sun gear4.FIG.14is a top view of the container ofFIG.1with all cover components10removed to reveal the interior space of the container.FIG.15is a top perspective view of the container ofFIG.1with the structure8supporting the planetary gears removed to reveal relationships between several planetary gears6and the sun gear and the cover components10removed to reveal the interior space26of the container. FIG.16is top view of a container with two images disposed on the door of the container where the first image is being displayed while the cover is disposed in the first closed state.FIG.17is top view of a container with two images disposed on the door of the container where the second image is being displayed while the cover is disposed in the second closed state. It shall be noted that, in the closed state ofFIG.16, the image that is displayed is the three concentric circles. As a relative rotation between the ring8-housing14is exerted on the container to cause the planetary gears to each rotate in the counterclockwise direction about axis of rotation34, the cover will eventually assume another closed state shown inFIG.17. Therefore, with only one cover, two images can be shown depending on the closed state at which the cover is disposed. It shall be noted that the image formed inFIG.17is of two concentric circles, i.e., an image that is different from the image inFIG.16although the cover components10in bothFIGS.16and17are the same cover components10. In one embodiment, the cover is configured to be disposed in one of two closed states and an angle of rotation between the two closed states is about 300 degrees. The cover components can be disposed in an open state from a closed state or disposed in a closed state from an open state with a relative rotation as little as 15 degrees, an angle of rotation which is significantly less than an angle of rotation required to open a hinged door fully, e.g., at least 90 degrees of rotation or for a sliding door, the traversal of the entire width of the door. FIG.18is a top view of a container with two images disposed on the door of the container where the first image is being displayed while the cover is disposed in the first closed state.FIG.19is a top view of a container with two images disposed on the door of the container where the second image is being displayed while the cover is disposed in the second closed state. It shall be noted that, in the closed state ofFIG.18, the main image that is displayed centrally is a circle. As a relative rotation between the ring8-housing14is exerted on the container to cause the planetary gears to each rotate in the counterclockwise direction about axis of rotation34, the cover will eventually assume another closed state shown inFIG.19. Therefore again, with only one cover, two images can be shown depending on the closed state at which the cover is disposed. It shall be noted that the image formed inFIG.19is of a star, i.e., an image that is different from the image inFIG.18although the cover components10in bothFIGS.18and19are the same cover components10. FIG.20is a top perspective view of a container with the cover components disposed in the fully open position where the cover components are positionally limited to the configuration shown;FIG.21is a top view thereof. It shall be noted that, in this embodiment, each of the cover components includes a stopper22and the cover is configured to be disposed in only one closed state. Here, in its open state, the cover components10together form a “star of David.” In one embodiment, the container can be used for storing valuables, e.g., an engagement ring, when the container is presented in a marriage proposal. FIG.22is a top view of a container with the cover components having edges28that are not rectilinear from the center of the cover to the outer perimeter of the cover where the cover is disposed in a closed state.FIG.23is a top view of a container with the cover components having edges that are not rectilinear from the center of the cover to the outer perimeter of the cover where the cover is disposed in an open state. In one embodiment, at least one of the cover components includes a sector including at least one edge that is non-rectilinear. It shall be noted that, the edges need not be rectilinear. For each cover component10, as long as the edges converge to a vertex at a central point of the opening and each of the planetary gear6is configured to rotate about an axis of rotation that coincides with a vertex of a polygonal opening shape, the cover components10can be moved from a cover open state to a cover closed state or from a cover closed state to a cover open state without interference. The detailed description refers to the accompanying drawings that show, by way of illustration, specific aspects and embodiments in which the present disclosed embodiments may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice aspects of the present invention. Other embodiments may be utilized, and changes may be made without departing from the scope of the disclosed embodiments. The various embodiments can be combined with one or more other embodiments to form new embodiments. The detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims, with the full scope of equivalents to which they may be entitled. It will be appreciated by those of ordinary skill in the art that any arrangement that is calculated to achieve the same purpose may be substituted for the specific embodiments shown. This application is intended to cover any adaptations or variations of embodiments of the present invention. It is to be understood that the above description is intended to be illustrative, and not restrictive, and that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Combinations of the above embodiments and other embodiments will be apparent to those of skill in the art upon studying the above description. The scope of the present disclosed embodiments includes any other applications in which embodiments of the above structures and fabrication methods are used. The scope of the embodiments should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. | 14,569 |
11859434 | DETAILED DESCRIPTION FIG.1provides a partial isometric view of a refrigerator R including at least one refrigerator door RD that is pivotally connected to a refrigerator body B and that pivots about a respective vertical axis between an open and closed position. Two doors RD are shown inFIG.1.FIG.1shows each door RD in its closed position.FIG.2provides an enlarged isometric view of one of the door hinge assemblies H of the refrigerator R ofFIG.1, with one of the doors RD in its opened position. In the closed position (FIG.1), the door(s) RD cover and seal an opening O (FIG.2) defined in a front wall FW of the body B and that provides access to a refrigerated or cold space CS that contains food and beverages, and when opened, the door(s) RD is (are) pivoted away from the opening O to allow user access to the cold space CS. The illustrated refrigerator R comprises two doors arranged in a French door style, but the refrigerator R can alternatively comprise only one of the doors RD that spans the entire height and width of the opening O. Typically, each refrigerator door RD is pivotally connected to the refrigerator body B by first (upper or lower) and second (lower or upper) hinge assemblies H, and at least one of the hinge assemblies H is formed in accordance with an embodiment of the present hinge assembly H as disclosed herein. In the present drawings, only a first hinge assembly H is shown in relation to each door RD, and those of ordinary skill in the art will recognize that the second hinge assembly can be identical to the illustrated first hinge assembly H, or the second hinge assembly can be provided in accordance with any other embodiment of the first hinge assembly described herein, or the second hinge assembly can be a conventional hinge assembly. Furthermore, the illustrated first hinge assembly H can function as either an upper hinge assembly located adjacent an upper edge UE of the door RD, or can function as a lower hinge assembly located adjacent a lower edge of the door RD that is located opposite the upper edge UE of the door. The various embodiments of the hinge assembly H provided in accordance with the present development are described herein with reference to a refrigerator door RD and body B, but the hinge assembly H can be used in connection with any other door for an appliance or non-appliance structure or application, and the pivot axis for the refrigerator door RD or other door need not be vertical but can alternatively be horizontal or otherwise oriented. The hinge assembly H provided in accordance with the present development comprises a hinge plate HP comprising an inner portion HP1that is flat or otherwise configured to abut an end wall EW of the refrigerator body B or other structure that is oriented perpendicular to the front wall FW, e.g., a bottom wall or the top wall of the refrigerator body B or other structure. As shown herein the hinge plate inner portion HP1is abutted with an end wall EW that provides the top wall of the refrigerator body B but it could alternatively be abutted with an end wall EW that provides the opposite bottom wall of the refrigerator body B. The hinge plate inner portion HP1includes apertures HPa adapted to receive rivets, screws, or other fasteners for securing the hinge plate inner portion to the end wall EW of the refrigerator body B or other structure at a location adjacent the intersection of the end wall EW with the front wall FW. The hinge plate HP further comprises an outer portion HP2that is connected to the inner portion HP1and that projects outwardly away from the inner portion HP1so as to project outwardly from and be cantilevered relative to the front wall FW. The hinge plate HP preferably comprises a one-piece metal plate structure such as a one-piece stamped metal body, but the hinge plate can alternatively be provided by a one-piece or multi-piece metallic and/or non-metallic structure. The door RD is pivotally connected to the outer portion HP2of the hinge plate HP. As shown herein, a door pivot stud or “thimble” TH is connected to the hinge plate outer portion HP2. The thimble TH includes a conical or cylindrical body portion TH1(FIG.2) that extends vertically from an inner side of the hinge plate HP and that is closely and slidably received in a mating thimble receiver TR comprising an opening located in the upper edge UE of the door in order to pivotally connect the door RD to the hinge plate HP and refrigerator body B. As noted above, a second hinge assembly (not shown), which can be the same or different from the first hinge assembly H, pivotally connects a lower edge of the door RD, which is located opposite the door upper edge UE, to the refrigerator body B in a similar manner. As described in more detail below, the door RD is vertically adjustable relative to the hinge plate HP and the mating connection between the cylindrical body portion TH1of the thimble TH and the thimble receiver TR accommodates such vertical movement of the door RD relative to the hinge plate HP. The thimble TH typically comprise a metal or polymeric structure. Alternatively, the door RD is pivotally connected to the hinge plate HP by a pin, stud, or any other structure connected to the hinge plate and/or connected to the door RD, and it is not intended that the present development be limited to the illustrated thimble TH for pivotally connecting the door RD to the hinge plate HP. The hinge assembly H comprises a damper system DS including a damper D adapted to be engaged and activated by the door RD or a structure connected to the door RD when the door RD pivots from its opened position (FIG.2) to its closed position (FIG.1) to control, slow, and otherwise damp movement of the door RD into its closed position to prevent harsh contact or “slamming” of the door into the front wall FW of the refrigerator body B upon closing. The hinge assembly H preferably comprises a damper engagement structure DE connected to and/or formed as part of the door RD and adapted to engage and activate the damper D upon movement of the door RD from its opened position to its closed position. In the embodiment ofFIGS.1-8, the damper engagement structure DE comprises a base plate PN1that is connected to the door upper edge UE using rivets or other fasteners and comprises an engagement pin PN2that projects vertically upward from the base plate PN1. The engagement pin PN2is preferably completely cylindrical or at least comprises a cylindrical outer surface where it contacts the damper D (i.e., the engagement pin PN2alternatively comprises a cylindrical arc segment or a partially cylindrical outer surface) to facilitate sliding tangential contact with the damper D during pivoting movement of the door RD toward its closed position, but the engagement pin PN2can alternatively comprise any other desired cross-sectional shape. Alternatively, the damper engagement structure DE comprises part of the door RD and/or a component connected directly or indirectly to the door RD. FIGS.2,3, and4respectively show the door RD in an opened position, a partially closed position (sometimes referred to as the “engaged” or “engagement” position), and the closed position in which the door RD is completely closed. Upon a comparison of these drawings, it can be seen inFIG.2that when the door RD is opened, the damper D is free or unconstrained and deactivated so that it assumes a normally extended position. Upon movement of the door RD in the closing direction, the engagement pin PN2initially contacts the damper D at the engagement position (FIG.3). Continued closing movement of the door RD from the engagement position results in the engagement pin PN2moving the damper D to a retracted position (FIG.4) against a damping force or resistance provided by the damper D such that the damper D is activated and slows movement of the door RD and damps or cushions movement of the door RD into the closed position to prevent slamming of the door RD against the refrigerator body B. The damper D is continuously biased toward its extended position such that when the refrigerator door RD is again opened and the engagement pin PN2is separated from the damper D, the damper D assumes its extended position/extended configuration in preparation for another damping cycle when the door RD is again closed. FIGS.5A and5Bare partial side views that both show the door RD in the partially closed or engaged position ofFIG.3.FIG.5Ashows the refrigerator door RD in its lowered state in which the door RD is configured to be vertically lowered relative to the body B and hinge plate second portion HP2, andFIG.5Bshows the refrigerator door RD in its raised state in which the door RD is configured to be vertically raised relative to the body B and hinge plate second portion HP2as compared to the lowered position ofFIG.5A. It can be seen that the vertically extending engagement pin PN2of the damper engagement structure beneficially ensures that the engagement pin PN2contacts the damper D when the door RD is in either its lowered position (FIG.5A) or its raised position (FIG.5B) or any position between the lowered and raised positions. The engagement pin PN2has a sufficient vertical height above the door upper edge UE that the damper D remains in vertical alignment with a portion of the engagement pin PN2for all vertical height adjustments of the door RD. Referring again toFIGS.2-4, in the illustrated embodiment, the damper D comprises a damper base DB connected to and/or formed as part of the hinge plate HP and a damper cylinder DC operably connected to and supported by the damper base DB. As shown herein, the damper base DB comprises a molded polymeric body that is connected to the inner portion HP1of the hinge plate HP using first and second rivets, screws, or other damper fasteners DF1, DF2that extend respectively through the first and second mounting apertures or openings DB1, DB2in the damper base DB and into the hinge plate HP. The damper base DB comprises a damper support bore DSB, and the damper cylinder DC is operably located in the damper support bore DSB such that the damper cylinder DC is positioned to be engaged and activated by the pin PN2or other part of the door RD or damper engagement structure DE upon closing of the door. FIGS.6,7, and8are top views that correspond toFIGS.2,3, and4, and in which the damper D and damper base DB are shown in section to reveal its internal components and operation. The damper cylinder DC comprises a cylinder body CB that includes a cylinder bore CR in which a piston PP is slidably supported for reciprocal sliding movement between an extended position (FIG.6) and a retracted position (FIG.8). A piston rod PR includes an inner end connected to the piston PP and includes an opposite outer end spaced from the piston rod inner end. The piston rod PR extends outwardly from the cylinder bore CR at and through a first end CB1of the cylinder body CB such that the inner end of the piston rod PR is located in the cylinder bore CR and the opposite outer end of the piston rod is located outside the cylinder bore CR and projects outwardly away from the first end CB1of the cylinder body CB. The cylinder body CB also includes a closed second end CB2located opposite the first end CB1. When the piston PP and piston rod PR are extended, the piston rod PR projects outwardly from the body first end CB1a greater extent as compared to when the piston PP and piston rod PR are retracted. When the piston PP and piston rod PR are retracted, the piston PP is moved away from the body first end CB1and toward the body second end CB2so that the piston rod PR is correspondingly retracted into the cylinder bore CR and projects outwardly from the body first end CB1a lesser extent as compared to when the piston PP is in its extended position. The extended and retracted positions of the piston PP correspond respectively to extended and retracted positions or states of the damper D, overall. In the illustrated example, the cylinder body CB is reciprocally slidable or movable in the damper support bore DSB. The damper fastener DF1that secures the damper base DB to the hinge plate HP intersects the damper support bore DSB and partially occludes an open inner end DSB1of the damper support bore DSB. As shown herein, the damper D is arranged with its piston rod PR oriented away from the engagement pin PN2and toward the damper fastener DF1and with the second end CB2of the cylinder body CB projecting outwardly from the open outer end DSB2(FIG.6) of the damper support bore DSB. In this arrangement, the outer end of the piston rod PR is abutted with the damper fastener DF1such that the damper fastener DF1provides a reaction member or stop against which the damper D is activated. Alternatively, the open inner end DSB1of the damper support bore DSB can be blocked or occluded by any other structure such as a plug, wall, screw, pin or the like to provide the stop against which the piston rod PR acts. Also, the orientation of the damper D in the damper support bore DSB can optionally be reversed so that the piston rod PR projects outwardly from the open outer end DSB2of the damper support bore DSB away from the first damper fastener DF1and the closed second end CB2of the cylinder body is located in the damper support bore DB and abutted with the damper fastener DF1. In this reverse orientation, the engagement pin PN2directly engages the outer end of the piston rod PR of the damper D and urges the piston PP from its extended position toward its retracted positon when the door RD is closed to activate the damper D such that it slows and otherwise damps movement of the door RD to into its closed position. A gas or liquid damping fluid and/or a mechanical damping spring is contained in the damper cylinder bore CR and acts on the piston PP to damp movement of the piston PP from the extended position toward the retracted position in response to inward movement of the cylinder body CB in the damper support bore DSB relative to the piston PP. Preferably, the piston PP is configured such that the damping fluid damps movement of the piston PP to a greater extent when the piston is moving from its extended position toward its retracted position (during inward movement of the cylinder body CB in the damper support bore DSB) as compared to the opposite direction of movement of the piston PP (during outward movement of the cylinder body CB in the damper support bore DSB) in order to facilitate a faster return or “reset” of the piston PP from its retracted position to its extended position when the refrigerator door RD is opened. The illustrated damper P includes a mechanical return spring such as a coil spring RS within the bore CR (shown partially only inFIG.6) to return the piston PP from its retracted position to its extended position when the damper D is not under load, i.e., to urge the cylinder body CB outwardly away from the damper fastener DF1. The return spring RS is alternatively externally located relative to the cylinder bore CR and coaxially positioned about the piston rod PR between the first end CB1of the cylinder body and a cap or spring stop connected to or formed as part of the outer end of the piston rod PR to bias the piston PP to its extended position relative to the cylinder body CB. FIG.9shows an alternative hinge assembly H2that is identical to the hinge assembly H except as otherwise shown and/or described herein. As such, like reference characters are used to identify like components, without repeating the structure and operation described above. Unlike the hinge assembly H ofFIGS.1-8in which the damper engagement pin PN2is separate from the hinge assembly, the hinge assembly H2comprises an integrated damper engagement structure DE′ comprising a base plate PN1′ and an engagement pin PN2′ projecting upwardly from the base plate PN1′. When the door RD pivots about a vertical pivot axis, the engagement pin PN2′ projects vertically outward/upward from the base plate PN1′. The base plate PN1′ is pivotally connected to the outer portion HP2of the hinge plate HP and comprises an aperture PN1athrough which the thimble body portion TH1extends such that the base plate PN1′ is rotatable about the thimble TH. The base plate PN1is affixed to the door upper edge UE and the base plate PN1′ rotates or pivots about the thimble TH relative to the hinge plate when the door RD is opened and closed. The engagement pin PN2′ operates as described above for the engagement pin PN2to engage and activate the damper D upon closing of the door RD to damp and cushion movement of the door into its closed position. FIG.10shows another alternative hinge assembly H3that is identical to the hinge assembly H except as otherwise shown and/or described herein. As such, like reference characters are used to identify like components, without repeating the structure and operation described above. In contrast to the hinge assembly H ofFIGS.1-8, or the hinge assembly H2ofFIG.9, the hinge assembly H3omits the engagement pin PN2and replaces it with a damper engagement arm AR that provides the damper engagement structure DE″. The damper engagement arm AR comprises a metal or polymeric plate structure that is pivotally connected to the outer portion HP2of the hinge plate HP and that includes an aperture ARa through which the thimble TH body portion TH1extends to rotatably connect the damper engagement arm AR to the hinge plate HP. The damper engagement arm AR is also secured to the door, such as to the upper edge UE thereof, and moves with the door RD pivotally about the thimble TH when the door moves between its opened and closed positions. The profile of the arm AR is such that it includes an inner edge AR1oriented toward the damper D when the door RD is closed, and the inner edge AR1of the arm is vertically located and conformed to be aligned with the damper D so that the inner edge AR1engages and activates the damper D when the door RD is moved from its opened position to its closed position such that the damper D moves toward its retracted position and slows and otherwise damps movement of the door RD into its closed position. FIGS.11A,11B and11Care section views that show an alternative damper system DS2that is identical to the damper system DS except as otherwise shown and/or described herein, and like reference characters are used to identify like components without further explanation, while similar components are identified with reference characters including a primed (′) designation. As such, the damper system DS2can be used in place of the damper system DS in the hinge assemblies H, H2, H3described above. The damper system DS2comprises a damper D′ that is identical to the damper D except for the shape of the cylinder body CB′ as described below.FIG.11Ashows the damper D′ in a first extended position,FIG.11Bshows the damper D′ is a second extended position, andFIG.11Cshows the damper D′ in its retracted position. The damper system DS2comprises a damper base DB′ that is adapted to be connected to and/or is formed as part of the hinge plate HP and that operably supports the damper cylinder DC′ of the damper D′ in the damper support bore DSB′. As shown inFIGS.11A-11C, the damper base DB′ comprises a molded polymeric body that includes first and second mounting apertures DB1′, DB2′ that receive respective damper fasteners for securing the damper base DB to the hinge plate HP. The damper base DB′ comprises a damper support bore DSB′ that extends through the damper base DB′, and the damper cylinder DC′ is operably located in the damper support bore DSB′ and adapted for reciprocal sliding movement in the damper support bore DSB′ as required for the damper D′ to provide damping force to counteract and cushion the closing movement of the door RD as described above for the damper system DS. The inner end DSB1′ of the damper support bore DSB′ is closed by a coaxially located set screw SC that is threaded into the inner end DSB1′ of the damper support bore, which includes internal threads for mating with the set screw SC. The cylinder body CB′ differs from the cylinder body CB in that it comprises a radially enlarged shoulder or flange CBF located between its opposite first and second ends CB1′, CB2′. The damper support bore DSB′ comprises a corresponding shoulder or step ST that projects radially inward from its inner wall at a location between its inner and outer ends DSB1′, DSB2′. The step ST of the damper support bore DSB′ and the shoulder CBF of the cylinder body CB′ are dimensioned and arranged relative to each other such that cylinder body CB′ is captured in the damper support bore DSB′ and is unable to escape the open outer end DSB2′, but the cylinder body CB′ is still able to slidably reciprocate in the damper support bore DSB′ between its extended and retracted positions as required for damping. The cylinder body CB′ is installed through the inner end DSB1′ of the damper support bore DSB′ when the set screw SC is removed. The installation of the set screw SC prevents the cylinder body CB′ from being removed from the damper support bore DSB′ through the inner end DSB1′, and engagement of the cylinder body shoulder CBF with the bore step ST prevents the cylinder body CB′ from being completely removed from the damper support bore DSB′ through the open outer end DSB2′, while still allowing reciprocation of the cylinder body CB′ between its extended and retracted positions. In addition to closing the open inner end DSB1′ of the damper support bore DSB′, the set screw SC also provides a reaction member or stop against which the outer end of the piston rod PR is abutted. Also, as can be seen by comparingFIGS.11A and11B, the axial position of the set screw SC in the damper support bore DSB′ can be adjusted by threadably advancing or retracting the set screw SC in the bore DSB′ which correspondingly alters the axial location of the damper D′ in the damper support bore DSB′ and also the distance that the second end CB2′ of the damper cylinder body CB′ projects outwardly from the damper support bore DSB′ when the cylinder body CB′ is in its extended position, i.e., the axial position of the set screw SC in the damper support bore DSB′ controls the maximum distance by which the cylinder body CB′ extends outwardly from the damper support bore DSB′ when the damper D′ is in its extended position. This adjustment correspondingly controls the angle in which the refrigerator door RD will be positioned relative to the refrigerator body B when the damper D′ is first engaged by the engagement pin PN2, engagement arm AR or other damper engagement structure DE of the door during closing of the door RD. It should be noted that the set screw SC as described can be used with the damper base DB and cylinder body CB in the damper system DS ofFIGS.1-10(without the cylinder body shoulder CBF and bore step ST). Also, the cylinder body CB′ including the shoulder CBF and the matching damper base DB′ with the bore step ST can be used in the embodiment of the damper system DS ofFIGS.1-10to capture the cylinder body CB in the damper support bore DSB of the damper base DB. FIGS.12and13show a damper system DSL that is identical to the damper system DS except as otherwise shown and/or described herein, and like components thereof are correspondingly identified in the drawings using a double-primed (″) designation, and further description of such components is not necessarily repeated below.FIG.12shows the damper D of the damper system DSL in the extended condition, andFIG.13shows the damper D of the damper system DSL in the retracted condition. The damper system DSL can be used in place of the damper system DS as described above or can alternatively be connected to the door RD, in which case the damper engagement structure DE is connected to and/or provided as a part of the appliance body B.FIGS.12A and13Aare section views of the damper system DSL as taken at A-A ofFIGS.12and13, respectively. Referring to all ofFIGS.12-13A, the damper system DSL comprises a damper base DB″ that is the same as the damper base DB except that the damper base DB″ is structured to include a lever mounting portion LMP to which a damper activation lever L is movably or pivotally connected at a lever pivot point LP by a rivet, pin, or other pivot fastener. The damper activation lever L pivots on an arc A (FIGS.12A,13A) between a first position (FIG.12) corresponding to the extended position of the damper D, and a second position (FIG.13) corresponding to the retracted position of the damper D. As shown in the illustrated example, the lever mounting portion LMP comprises a clevis, but a single tab or other structure can alternatively provide the lever mounting portion LMP. The lever mounting portion LMP or the damper base DB″ includes at least one stop surface or “stop” ST, and the lever L abuts the stop(s) ST when the lever L is in its first position to prevent pivoting movement of the lever L away from its second position beyond the first position. The mounting apertures DB1″, DB2″ of the damper base DB″ are relocated as compared to the damper base DB to accommodate the lever mounting portion LMP. Otherwise, the damper base DB″ is similar to the damper base DB and comprises a damper support bore DSB in which the damper D is operably supported for reciprocal sliding movement between its extended as retracted positions as described above for the damper system DS. Because the lever L abuts the stop(s) ST in its first position, the lever L traps or captures the damper D in the damper support bore DSB. Unlike the damper system DS, the damper D of the damper system DSL is indirectly acted upon by the damper engagement structure DE through the lever L. More particularly, when connected to the appliance body B, the damper system DSL is adapted to be mounted to the hinge plate HP in place of the damper system DS as shown inFIGS.1-10, such that the damper activation lever L is oriented outwardly and the engagement pin PN2or other damper engagement structure DE engages an outer surface LS of the lever L and pivots the lever L from its first position (FIG.12) toward and into its second position (FIG.13) on the arc A during movement of the door RD from its opened position toward and into its closed position. During closing movement of the door RD, the lever L is contacted by the damper engagement structure DE and pivoted from its first position toward its second position such that a tip LT or other portion of the lever L contacts the second end CB2of the damper cylinder body CB and urges the damper cylinder body CB inwardly such that the damper D is activated and moves toward its retracted position and provides a damping force to slow closing movement of the door RD. When the door RD is again opened, the damper return spring RS moves the damper D to its extended position, and the damper D correspondingly exerts a force on the lever L that pivots the lever L on the arc A back toward and into its first position. As with the damper system DS, the damper D of the damper system DSL can be reversed so that the second end CB2of the cylinder body is oriented toward and located adjacent the innermost end DSB1of the damper support bore DSB and so that the piston rod PR projects outwardly from the outer end DSB2of the damper support bore DSB and is located to be engaged and acted upon by the damper activation lever L for movement of the piston PP between its extended and retracted positions. FIGS.14and15show a hinge assembly H4that is identical to the hinge assembly H except as otherwise shown and/or described herein, and like components thereof are correspondingly identified in the drawings with a primed (′) or similar designation and are not necessarily described further below. The hinge assembly H4provides an example of a hinge assembly in which the damper system DSL is connected to the door RD instead of the hinge plate HP or the appliance body B. More particularly, the damper base DB″ is secured to the upper edge UE or other part of the door RD with the outer surface LS of the lever L oriented toward the door pivot stud/thimble TH and with the tip LT of the lever oriented away from the front wall FW of the body B when the door RD is located in its closed position adjacent the front wall FW. In the illustrated example, the damper system DSL is installed such that the damper D is arranged to lie in-line with the door RD, i.e., parallel to the inner and outer walls IW, OW of the door RD and parallel to the front wall FW of the refrigerator body B when the door RD is closed. Preferably, the tip LT of the lever is oriented toward the outer wall OW of the door RD. This in-line arrangement of the damper system DSL allows most of the damper system DSL to be hidden from a user behind a plastic or similar door cap CP (FIG.14) for improved aesthetics and to discourage user contact and tampering with the damper system DSL. To activate the damper system DSL, the appliance body B or another structure connected to or provided as part of the appliance body B comprises a damper engagement portion. As shown herein, a hinge plate HP′ is similar to the hinge plate HP described above except that it comprises a damper engagement portion DE″, such as an edge or other structure of the outer portion HP2′, that is dimensioned and conformed to engage the outer surface LS of the damper system lever L when the door RD is moved from its opened position toward its closed position such that the damper D is activated by the lever L during such movement of the door RD toward its closed position as shown inFIG.15. In particular, the damper engagement portion DE′″ is configured to contact the lever outer surface LS as the door RD moves from its opened position toward its closed position when the door RD reaches a select door angle engagement position relative to the body B as the door RD nears its closed position, e.g., when the door RD is located at a door angle DA in the range of 5 degrees to 20 degrees or any other desired door angle DA as measured between a vertical reference plane the door RD that lies parallel to the inner and outer walls IW, OW and the front wall FW of the body B as shown inFIG.15. Further movement of the door RD toward its closed position from the engagement position shown inFIG.15causes the damper engagement portion DE′ to pivot the lever L on the arc A toward its second position to activate the damper D and move the damper toward its retracted position. In this regard, the lever L translates the motion of the door 90 degrees to activate the damper D. When the door RD is pivoted in the opposite direction from its closed position toward its opened position, the lever L is disengaged from the damper engagement portion DE′ of the hinge plate HP and the damper return spring RS urges the damper D to its extended position which moves the lever L back to its first position to reset the damper system DSL. The damper engagement portion DE′ is shaped and dimensioned to control or vary the door angle DA at which the damper engagement portion DE′″ first contacts the outer surface LS of the lever L during movement of the door RD from its opened position toward its closed position. This allows the closing characteristics of the door RD to be adjusted for a particular application such that the damper D is activated at the desired door angle DA to ensure that the door RD closes with the desired speed and closing force. For example, when used with a French door refrigerator R as shown inFIG.1, it is often desired to delay activation of the damper D until a vertical articulating mullion located between the two doors RD is partially or fully deployed before activating the damper D during closing of the door, to ensure that the damper D does not interfere with full closing of the door RD. Likewise, the damper engagement portion DE′ is also shaped and dimensioned to control or vary the location on the lever outer surface LS at which the damper engagement portion DE′″ contacts the outer surface LS of the lever L during movement of the door RD from its opened position toward its closed position, and this varies the dynamics of the forces acting on the lever L and damper D. In particular, as the contact location of the damper engagement portion DE″ on the lever outer surface LS moves outwardly away from the lever pivot point LP toward the lever tip LT, the damping force provided by activation of the damper D is decreased while the effective damping stroke of the damping system DSL is lengthened, i.e., the damper D provides damping force over a wider angle of movement of the door RD as the contact location between the damper engagement portion DE′″ and the lever L is moved outwardly away from the lever pivot point LP. In contrast, as the contact location of the damper engagement portion DE′ on the lever outer surface LS moves inwardly toward the lever pivot point LP, the damping force provided by activation of the damper D is increased but the effective damping stroke of the damping system DSL is shortened, i.e., the damper D provides damping force over a smaller angle of movement of the door RD as the contact location between the damper engagement portion DE′″ and the lever L is moved inwardly toward the lever pivot point LP. Also, the damper engagement portion DE′″ is optionally shaped so that its contact location with the outer surface LS of the lever L changes as the door RD closes so that the damping force provided by the damper D varies as the door closes to provide a dynamic damping effect. In one example, this feature is implemented so that the damper D provides increased damping force as the door approaches its fully closed position, e.g., during the final two—four degrees of closing movement of the door, which allows the damper D to be generally lighter duty to reduce cost while still providing the required damping effect. In an alternative embodiment, the damper engagement portion DE″ is not provided by the hinge plate HP′ but is, instead, provided by a hinge cap or cover that is located adjacent the hinge plate or is provided by any other part of the refrigerator body B or a component connected thereto and located adjacent the hinge plate HP. FIG.16shows an alternative hinge assembly H5that is identical to the hinge assembly H4except as otherwise shown and/or described herein. As such, like reference characters are used to identify like components, without repeating the structure and operation described above. Unlike the hinge assembly H4, the hinge assembly H5further comprises a damper system mounting plate DMP that is pivotally connected to the hinge plate HP′ by way of the door mounting stud/thimble TH so as to be integrated with the hinge plate HP′ but rotatable about the door mounting stud/thimble TH. The damper system DSL is secured to the damper system mounting plate DMP, which is, itself, secured to the upper edge UE of the door RD. This arrangement can simplify installation of the hinge assembly H5onto the body B and door RD. FIG.17illustrates an alternative damper system DSL′ that is identical to the damper system DSL except as otherwise shown and/or described herein. In particular, the damper system DSL′ comprises a modified damper base ADB″ that is similar to the damper base DB″ except that the damper mounting apertures DB1″, DB2″ are relocated to so that the base ADB″ can be structured to include an adjustable set screw SC as described with reference toFIGS.11A-11G. In such case, the damper D need not be provided as a damper D′ (and the damper support bore need not be correspondingly provided as the damper support bore DSB′) as described with reference toFIGS.11A-11C, because the lever L captures the damper D in the damper support bore DSB as described above. Advancement or retraction of the set screw SC in the damper support bore DSB alters the distance by which the damper D projects outwardly from the damper support bore DSB to provide some adjustability for the door angle DA at which the lever L contacts the damper engagement portion DE′″ during movement of the door RD from the opened position to the closed position. As noted above, the damper system DSL is not limited for use with refrigerator doors RD or other appliance doors. The damper system DSL can alternatively by used to damp the movement of any other door relative to a frame, body, or other structure to which the door is pivotally connected. In such case, the door can be arranged to pivot about a vertical axis, a horizontal axis, or any other pivot axis. The development has been described with reference to preferred embodiments. Modifications and alterations will occur to those of ordinary skill in the art to which the invention pertains, and it is intended that the claims be construed as broadly as possible to encompass all such modifications and alterations while preserving the validity of the claims. | 37,066 |
11859435 | DETAILED DESCRIPTION Various apparatuses or processes will be described below to provide an example of an embodiment of each claimed invention. No embodiment described below limits any claimed invention and any claimed invention may cover processes or apparatuses that differ from those described below. The claimed inventions are not limited to apparatuses or processes having all of the features of any one apparatus or process described below or to features common to multiple or all of the apparatuses described below. It is possible that an apparatus or process described below is not an embodiment of any claimed invention. Any invention disclosed in an apparatus or process described below that is not claimed in this document may be the subject matter of another protective instrument, for example, a continuing patent application, and the applicants, inventors, or owners do not intend to abandon, disclaim, or dedicate to the public any such invention by its disclosure in this document. Referring toFIG.1, an example sliding sash assembly100is illustrated. In the example illustrated, the sliding sash assembly100is configured for use as a sliding door. The sliding sash assembly100is configured for installation in a wall separating an interior space from an exterior space, with an exterior face of the assembly100directed toward the exterior space, and an interior face of the assembly100directed toward the interior space. The sliding sash assembly100includes an assembly frame104defining a frame opening106(i.e. a doorway in the example illustrated), and a pair of sashes110mounted in the frame opening106. At least one of the sashes110is slidable relative to the frame104along an opening axis108. The pair of sashes110include a first sash110aand a second sash110b. In the example illustrated, the first sash110ais fixed in position relative to the assembly frame104, and the second sash110bis slidable relative to the frame104along the opening axis108between a closed position (shown inFIG.1) and an open position (shown inFIG.2). In some examples, both sashes can be operable for selectively closing and opening the doorway. Referring toFIG.1, when in the closed position, the second (operable) sash110bis aligned with, and covers, an opening between the fixed sash110aand a distal (second) jamb member105b. Referring toFIG.2, when in the open position, the operable sash110bis retracted away from the second jamb105b, uncovering a first portion of the frame opening106(defined, in the illustrated example, by the horizontal extent106a). Referring toFIG.1, in the example illustrated, the assembly frame104includes a plurality of assembly frame members105extending about and defining the assembly frame opening106. The assembly frame members105include a pair of first and second vertical jamb members105a,105bspaced horizontally apart from each other, and a pair of horizontal members including a sill105cand a header105d, spaced vertically apart from each other and joined at opposed ends to the first and second jamb members105a,105b. In the example illustrated, each sash110includes a plurality of sash frame members111extending about and defining a sash opening109in which, in the example illustrated, a glazing unit is mounted. The plurality of sash frame members111includes a pair of first and second vertical stiles111a,111bspaced horizontally apart from each other, and a pair of third and fourth (lower and upper) horizontal rails111c,111dspaced vertically apart from each other with opposed ends joined to the first and second stiles111a,111b. The first stile111aof each of the first and second sashes110a,110bis positioned toward the first and second jamb members105a,105b, respectively, for engagement therewith when the sashes110are in the closed position. The second stiles111bof the first and second sashes are located axially inwardly of the respective first stiles111a. In the example illustrated, when the assembly100is in the closed position, the first stile111aof the first sash110ais in engagement with the first jamb member105a, the first stile111aof the second sash110bis in engagement with the second jamb member105b, and the second stiles111bof the first sash110aand the second sash110boverlap and inter-engage with each other. In the example illustrated, the second stiles111binclude inter-engaging features to hold the second stiles111bof the sashes110snugly together (typically with weatherstripping disposed therebetween) and help seal out the weather. When the operable sash110bis in the open position, the first stile111aof the second sash110bis spaced apart from the second jamb member105bby, for example, the first extent106a(FIG.2). In the example illustrated, when the operable sash110bis moved from the closed position to the open position, the operable sash110bslides along a travel path parallel to the axis108relative to the first sash110a. More particularly, with reference toFIG.2, in the example illustrated, the header and sill105c,105dprovide a track113to retain the operable sash110bin sliding engagement within the assembly frame104. The track113can include elongate tongue and groove members oriented parallel to the opening axis108. The lower and upper rails111c,111dof the operable sash110bcan include complementary tongue and groove members, also oriented parallel to the opening axis108, and in sliding engagement with the tongue and groove members of the track113of the frame assembly104. The track113defines the travel path of the second sash110band is offset toward the interior face of the assembly100relative to the first sash110a. During opening, the second sash110bslides in front of the first sash (when viewed from the interior side), with a rear (exterior-facing) surface of the second sash110bsliding along, and/or in close proximity to, a front (interior-facing) surface of the first sash110a. Referring toFIG.1, in the example illustrated, the sliding sash assembly100includes at least one stop device112. In the example illustrated, the stop device112is mounted to the first (fixed) sash110a, and in the example illustrated, is mounted along a front (interior-facing) surface of the lower rail111cof the first sash110a. The stop device112is positioned axially between a first end of the lower rail111cjoined to the first stile111aof the first sash110a, and a second end of the lower rail111cjoined to the second stile111bof the first sash110a. When the second sash110bis in the closed position, the stop device112is positioned axially (along axis108) between the first jamb member105aof the assembly frame104and the second stile111bof the second sash110b. In the example illustrated, the stop device112has a housing114fixed to the first sash110a, and extending along a housing axis115. In the example illustrated, the housing axis115extends parallel with the opening axis108. In the example illustrated, the stop device112further includes a pair of depressible stop members116movably mounted in the housing114. In the example illustrated, the stop members116include a first stop member116aand a second stop member116bspaced apart from each other along the axis108(and the housing axis115). Each stop member116is selectively movable independent of the other stop member116between a retracted position and an advanced position. Referring toFIG.5A, when the stop member116is in the retracted position (see e.g. the second stop member116binFIG.5Aand the first stop member116ainFIG.5B), the stop member116is retracted into the housing114clear of the travel path of the second sash110b(FIG.1). When in the advanced position (see e.g., the first stop member116ainFIG.5Aand the second stop member116binFIG.5B), the stop member116projects from the housing114at a corresponding stop position along the opening axis108into the travel path of the second sash110bfor engagement with the second sash110bto restrict movement of the pair of sashes110toward the open position. In the example illustrated, each stop member116is translatable between the retracted and advanced positions along a corresponding stop member axis118extending perpendicular to the opening axis108(and the housing axis115). Referring toFIG.1, the stop position of the first stop member116acorresponds to the closed position to prevent movement of the pair of sashes110from the closed position. In the example illustrated, the stop position of the first stop member116ais immediately adjacent the second stile111bof the second sash110bwhen the sashes110are in the closed position. Referring toFIG.3, the stop position of the second stop member116bcorresponds to a partially-open position of the pair of sashes110. The partially-open position is between the open and closed positions for uncovering a second extent106bof the frame opening106that is less than the first extent106a. In the example illustrated, when the sashes110are in the partially-open position, the first stile111aof the second sash110bis spaced apart from the second jamb member105bby the second extent106bof the frame opening106. In the example illustrated, the second extent106bextends along the opening axis108between the first stile111aof the second sash110band the second jamb member105b. The second extent106bcan be, for example, equal to or less than 4 inches (about 10 cm). In the example illustrated, each stop member116has an abutment surface117directed generally perpendicular to the opening axis108toward the second sash110b(when the sashes110are in the closed position) for engagement with a horizontally inward surface of the stile111bof the second sash110bat a corresponding stop position. The abutment surfaces117of the stop members116a,116bare spaced apart from each other along the opening axis108by an abutment surface spacing119(FIG.5A) corresponding to the second extent106b. In some examples, the abutment surface spacing119is greater than the second extent106bto, for example, accommodate the second sash110bbeing received in a pocket of the second jamb member105b. For example, in examples in which the second extent106bis about 4 inches, the abutment surface spacing119can be, for example, 4.75 to 5 inches (e.g. to accommodate a pocket depth in the second jamb member105bof about 0.75 to 1 inches). When the sashes110are in the partially-open position, the first stile111aof the second sash110bis positioned along the opening axis108between the first stile111aof the first sash110aand the second jamb member105b, and the second stile111bof the second sash110bis positioned along the opening axis108between the first and second stiles111a,111bof the first sash110a. In the example illustrated, each sash110has an inboard face120directed toward the other sash110and an outboard face122opposite the inboard face120. The inboard face120of the first sash110aand the outboard face122of the second sash110bare directed toward the interior space and define a portion of the interior face of the assembly100. The outboard face122of the first sash110aand the inboard face120of the second sash110bare directed toward the exterior space and define a portion of the exterior face of the assembly100. In the example illustrated, the stop device112is mounted to the inboard face120of the first sash110a, and the stop member axis118(FIG.5A) is perpendicular to the inboard face120of the first sash110a. In the example illustrated, each stop member116is generally flush with, or retracted relative to, the inboard face120of the first sash110awhen in the retracted position to permit translation of the inboard face120of the second sash110bpast the stop member116. Each stop member116projects forward (interiorly) from the inboard face120of the first sash110awhen in the advanced position, into the opening path for engagement with a leading outer surface of the second stile111bof the second sash110b. In the example illustrated, a mounting aperture123(FIG.3) is provided in the inboard face120of the first sash110a, and the housing114is positioned in the mounting aperture123clear of the travel path of the second sash110b. Referring toFIG.6, in the example illustrated, the housing114has a pair of cavities124spaced apart from each other along the opening axis108and open in a frontward direction normal to the inboard face120of the first sash110a. Each stop member116is movably retained in a corresponding cavity124for translation along the stop member axis118between the retracted and advanced positions. In the example illustrated, the stop member116has a front wall125adjacent an opening of the cavity124and a plurality of sidewalls127extending rearwardly from the front wall125and slidably received in the cavity124adjacent corresponding guide surfaces in the cavity124for guiding translation of the stop member116along the stop member axis118. Referring toFIGS.6and6A, in the example illustrated, each stop member116is held in fixed position along the housing axis115relative to the housing114(and the cavity124). In the example illustrated, the stop member116is held axially captive (along the housing axis115) between a pair of cavity surfaces126a,126bin the cavity124and fixed relative to the housing114. The cavity surfaces126a,126bare spaced apart from and face each other along the housing axis115. In the example illustrated, the stop member116has an outer sidewall surface129axially opposite the abutment surface117along the housing axis115and facing the cavity surface126bfor engagement therewith to facilitate force transfer from the stop member116(e.g. when engaged by the sash110b) to the housing114. In the example illustrated, the abutment surface117has an abutment surface front edge117aand the sidewall surface129has a sidewall surface front edge129apositioned rearward of the abutment surface front edge117a(along the axis118). When the stop member116is in the advanced position, the abutment surface front edge117ais spaced forward of the housing114, and the sidewall surface front edge129ais adjacent the housing114. The front wall125extends along the housing axis115from the abutment surface front edge117ato the sidewall surface front edge129a. The front wall125has a forward portion125aadjacent the abutment surface front edge117aand a sloped portion125bsloping rearwardly along the stop member axis118from the forward portion125ato the sidewall surface front edge129a. This can facilitate force transfer through the front wall125from the abutment surface117(e.g. when engaged by the sash110b) to the housing114(e.g. through engagement between the sidewall surface129and the cavity surface126b). In the example illustrated, each cavity124extends along a cavity axis parallel with the stop member axis118, and the housing has a flange portion130extending laterally outwardly from an upper periphery of each cavity124and positioned generally flush against the inboard face120of the first sash110a. In the example illustrated, the housing114has a plurality of snap fit connectors128extending downwardly from an underside of the flange portion130for securing the housing114in the mounting aperture123through a snap-fit connection. In the example illustrated, the housing114is of integral, unitary, one-piece construction. In the example illustrated, the stop device112includes a plurality of springs132in the housing114, and each spring132biases a corresponding stop member116toward the advanced position. The stop device112further includes a plurality of push-activated latch mechanisms134. Each latch mechanism134is operable to selectively latch and maintain a corresponding stop member116in the retracted position (e.g. through depression of the stop member116from the advanced position and past the retracted position). Each latch mechanism134is operable to selectively release the stop member116from the retracted position for biased movement toward the advanced position (e.g. through depression of the stop member116when latched in the retracted position further past the retracted position). Referring toFIG.4, in the example illustrated, the sliding sash assembly100includes a pair of the stop devices112a,112bspaced apart from each other across the frame opening106perpendicular to the opening axis108. In the example illustrated, the stop positions of each stop device112a,112bare in alignment with corresponding stop positions of the other stop device112a,112balong the opening axis108. In the example illustrated, a first one of the stop devices112ais mounted to the lower rail111cof the first sash110aand the second one of the stop devices112bis mounted to the upper rail111dof the first sash110a. Referring toFIG.7, another example stop device1112is shown mounted to a sash1110of a sash assembly (like the assembly100). The sash1110and stop device1112have similarities to the sash110and stop device112, respectively, and like features are identified with like reference numerals, incremented by 1000. In the example illustrated, the stop device1112includes a housing1114extending along a housing axis1115and mounted to an inboard face1120of the sash1110. A pair of depressible stop members1116are movably mounted in the housing1114and spaced apart from each other along the housing axis1115. Each stop member1116is translatable perpendicular to the housing axis1115independent of the other stop member1116between a retracted position (FIG.8), in which the stop member1116is retracted into the housing1114, and an advanced position (FIG.9) in which the stop member1116projects from the housing1114for engagement with another sash of the sash assembly to limit movement of the sashes toward an open position. Referring toFIGS.7to9, in the example illustrated, the housing1114is of two-piece construction, and includes a housing first portion1114ain which a first stop member1116ais movably mounted, and a housing second portion1114bin which a second stop member1116bis movably mounted. In the example illustrated, the housing first and second portions1114a,1114bare identical and mounted together side-by-side and in abutting relation in a common mounting aperture in the inboard face1120of the sash1110. Referring toFIGS.10and11, another example sliding sash assembly2100is illustrated. In the example illustrated, the sliding sash assembly2100is configured for use as a vertically sliding window. The sliding sash assembly2100includes an assembly frame2104defining a frame opening2106(i.e. for a window opening in the example illustrated), and a pair of sashes2110mounted in the frame opening1106. The pair of sashes2110include a first sash2110aand a second sash2110b. In the example illustrated, the first sash2110ais fixed in position relative to the assembly frame2104, and the second sash2110bis slidable relative to the frame2104along an opening axis2108between a closed position (FIG.10) and an open position. In the example illustrated, when the second sash2110bis moved from the closed position to the open position, the second sash2110bslides along a travel path parallel to the axis2108relative to the first sash2110a. In the example illustrated, the sliding sash assembly2100includes at least one stop device2112. In the example illustrated, the stop device2112is mounted to the first (fixed) sash2110a. In the example illustrated, the stop device2112has a housing2114fixed to the first sash2110aand a pair of depressible stop members2116movably mounted in the housing2114. In the example illustrated, the stop members2116include a first stop member2116aand a second stop member2116bspaced apart from each other along the axis2108. Each stop member2116is selectively movable independent of the other stop member2116between a retracted position and an advanced position. When the stop member2116is in the retracted position (see e.g. the second stop member2116binFIG.10), the stop member2116is retracted into the housing2114clear of the travel path of the second sash2110b. When in the advanced position (see e.g., the first stop member2116ainFIG.10), the stop member2116projects from the housing2114at a corresponding stop position along the opening axis2108into the travel path of the second sash2110bfor engagement with the second sash2110bto restrict movement of the pair of sashes2110toward the open position. Referring toFIG.10, the stop position of the first stop member2116acorresponds to the closed position to prevent movement of the pair of sashes2110relative to each other from the closed position. Referring toFIG.13, the stop position of the second stop member2116bcorresponds to a partially-open position of the pair of sashes2110. The partially-open position is between the open and closed positions for uncovering a second extent2106bof the frame opening2106that is less than a first extent corresponding to the open position. | 20,737 |
11859436 | DETAILED DESCRIPTION Aspects of the disclosure are described more fully hereinafter with reference to the accompanying drawings, which form a part hereof, and which show, by way of illustration, example features. The features can, however, be embodied in many different forms and should not be construed as limited to the combinations set forth herein; rather, these combinations are provided so that this disclosure will be thorough and complete, and will fully convey the scope. The following detailed description is, therefore, not to be taken in a limiting sense. Interior millwork for residential and commercial housing are decorative, nonstructural components normally made of strips of wood and used to cover transition areas between surfaces. These components, called “mouldings” or “moldings,” include casings/case moldings, base moldings, and crown moldings, and can be used to trim the perimeter of windows, doors, and locations where walls meet a floor or a ceiling. Vertical and horizontal millwork trim pieces that cover door openings are called door jambs. Vertical door jambs bear the weight of the door through applied hinges and latches. Two vertical jamb sides and a head jamb may be referred to as a door jamb set. A door jamb set hinged to a door may be referred to as a prehung door. The accuracy of the plumb and strength of a door jamb is important to the overall operational durability and security of a door. Today, millwork also encompasses items that are made using alternatives to wood, including synthetics, plastics, and wood-adhesive composites. Millwork may be painted or stained (e.g., after installation). Referring generally toFIGS.1through32, composite trim molding assemblies, such as door jamb assemblies100for a door jamb set are described. A door jamb assembly100can include an outer one-piece shell102covering a strengthening and stiffening core104. The door jamb assemblies100can be used for interior doorway applications. For example, a door106can be attached to an interior door jamb assembly100by hinges108fastened to the door jamb assembly100by fasteners (e.g., screws110) extending into the door jamb assembly100. A door jamb assembly100can also include other hardware, such as a strike plate112and so forth. A door jamb assembly100can be fastened to the doorframe by fasteners (e.g., nails114) extending through a side of the door jamb assembly100and into the framing studs (e.g., jack stud101) and/or header103of the doorframe. For example, a doorframe may be formed by a king stud101and a jack stud101on one side of the doorframe (with additional framing studs mirrored on the other side of the doorframe) and a header103at the top of the doorframe. The side of the door jamb set formed by a door jamb assembly100that attaches the hinges108can include hinge cutouts107and forms a hinge jamb109. In other embodiments, the door jamb assembly100does not necessarily include the hinge cutouts107. For instance, cutouts may be added during installation of the door106. The other side of the door jamb set formed by a door jamb assembly100that attaches the strike plate112can include a mortise111(e.g., for the strike plate112) and forms a latch jamb113. The top of the door jamb set formed by a door jamb assembly100forms a head jamb115. The door can include a latch bolt bore117for a latch bolt to interface with the strike plate112/mortise111and a lockset bore119. After the door jamb set is anchored to the rough opening, finishes such as drywall121and casings123can be added to complete the installation. The shell102can be formed of a composite material (e.g., engineered wood formed from wood dust (e.g., sawdust), shavings, fibers, fillers, etc.) and shaped into a flat jamb116. In some embodiments, the shell102may also include one or more surface features, such as a stop118. In embodiments of the disclosure, the shell102can be molded from slurry, pressed from a flat composite panel, and so forth. For example, in some embodiments, the shell102can be molded cellulosic fiberboard, which can be formed from a pre-consolidated mat. The pre-consolidated mat can be formed into consolidated medium-density fiberboard (MDF), hardboard, softboard, low-density fiberboard, and so forth. For instance, hardwood and/or softwood residuals can be broken down into fillers or fibers (e.g., using a defibrator or another pulping machine, grinding, explosion hydrolysis, etc.), and the resulting wood fillers or fibers can be formed into a loose mat along with a binding agent and/or resin and/or wax and compressed under high temperature and pressure to form a shell102. In some embodiments, the pre-consolidated cellulosic mat may be planar. However, when molded to form the shell102, various shaped molds may be used to form surface features (e.g., an embossed texture, such as a faux wood grain pattern surface texture126) and/or contours (e.g., an interior extension or depression, such as stop118). In some embodiments, a shell102may also have one or more smooth exterior surfaces. Further, the edges and/or sides of the door jamb assembly100may include various edge details, including, but not necessarily limited to: back beveled details (e.g., as described with reference toFIGS.16and17), square details (e.g., as described with reference toFIGS.12and13), trim guide details (e.g., as described with reference toFIGS.18through21), and so on. For instance, edge details may be provided for resting and/or registering the casing123. In some embodiments, the shell102may not completely extend around the core104. For example, with reference toFIGS.31and32, a portion of the core104may be wider than the interior cavity of the shell102and may extend to be parallel to, for instance, edges of the shell102. As described, the shell102may have a generally uniform cross-sectional thickness. In some embodiments, the pre-consolidated cellulosic mat can be formed in a wet process, e.g., where cellulosic fillers or fibers in a slurry having a high moisture content (e.g., about ninety percent (90%) water or more by weight) and a synthetic resin binder (e.g., phenol-formaldehyde resin) are deposited onto a water permeable support (e.g., a fine screen, mesh, wire, etc.). Moisture is then removed to leave a wet mat of cellulosic material having a lower moisture content (e.g., about fifty percent (50%) water by weight). The wet mat can then be molded under high temperature and pressure to form the composite material shell102. In some embodiments, the pre-consolidated cellulosic mat can be formed in a wet-dry process, e.g., where a large amount of moisture from a wet mat is evaporated prior to molding (e.g., leaving the mat with a water content of about ten percent (10%) or less by weight). Further, a pre-consolidated cellulosic mat can be formed in a dry process, e.g., where cellulosic fibers are conveyed mechanically or in a gas stream rather than in a liquid. For example, cellulosic fibers may be coated with thermosetting resin binder (e.g., phenol-formaldehyde resin) and formed into a mat by blowing the coated fibers onto a support. In some embodiments, the shell102may be formed as a thin-layered wood composite including lignocellulose/lignocellulosic fiber and a polymer resin. The term lignocellulose refers to plant dry matter (biomass) including carbohydrate polymers (cellulose, hemicellulose) and an aromatic polymer (lignin). The lignocellulose composite mixture may have about 70% to about 99% by weight lignocellulosic fiber. The lignocellulosic fiber can have a range of moisture levels and may be dehydrated prior to treatment with the resin. For example, the lignocellulosic fiber can have from about 2% to about 20% moisture content by weight. In embodiments, the resin may be a formaldehyde-based resin, an isocyanate-based resin, and/or another thermoplastic or thermoset resin. In some embodiments, the amount of resin may range from about 1% to about 25% by weight of the composite. The lignocellulosic composite mixture may also include one or more waxes (e.g., a natural wax and/or a synthetic wax, such as paraffin wax, polyethylene wax, polyoxyethylene wax, microcrystalline wax, shellac wax, ozokerite wax, montan wax, emulsified wax, slack wax, etc.). The thin-layer composites may also include a pre-press sealer (e.g., a liquid material applied to the surface of a mat used to formulate the thin-layer composite prior to the mat entering a press). The lignocellulosic mixtures may be pressed into a thin-layer using flat or molded dies at high temperature and/or pressure. The mixture may initially be formed into a loose mat then placed into a die press. With reference toFIG.33, a two-part mold, such as a die press130(e.g., having a first die132and a second die134) may be used to form the shell102. For example, a pre-consolidated mat can be placed into the die press130and formed into consolidated medium-density fiberboard (MDF), hardboard, softboard, low-density fiberboard, and so forth. As described, hardwood and/or softwood residuals broken down into fillers or fibers can be formed into a loose mat along with a binding agent and/or resin and/or wax and compressed under high temperature and pressure in the die press130to form the shell102. In some embodiments, one or more walls136of the first die132and/or the second die134may be formed with a negative camber or positive draft (e.g., for more easily releasing from the die press130). For example, walls136of the first die132and/or the second die134may slope outwardly and downwardly when viewed from an end, allowing the shell102to more easily release from the dies after formation. In some embodiments, one or more walls136of the first die132and/or the second die134may be formed with a zero camber or zero draft (e.g., at an angle of about ninety (90) degrees from an adjacent surface, as described with reference toFIGS.34and35). In some embodiments, one or more walls136of the first die132and/or the second die134may be formed with a positive camber or negative draft. For example, walls136of the first die132and/or the second die134may slope inwardly and downwardly when viewed from an end, providing a back bevel. Referring toFIGS.34and35, in an example configuration where, for instance, walls136of the first die132and/or the second die134are formed with a negative camber or positive draft and/or with a zero camber or zero draft, a back bevel (FIG.34) and/or trim guide (FIG.35) feature may be provided by a trimming or machining operation. For example, a back bevel138and/or a trim guide140may be provided by cutting, shaving, milling, or otherwise trimming material from the shell102to thin the shell from a first thickness t1to a second thickness t2. However, a trimming or machining operation is provided by way of example and is not meant to limit the present disclosure. In other embodiments, a die (e.g., first die132and/or second die134) may include a movable segment configured to form a feature that provides positive camber or negative draft. In this configuration, the movable segment may be positioned to create a feature with positive camber or negative draft (e.g., the back bevels shown on the shells102as illustrated inFIGS.16and17and/or the notches shown on the interior of the shells102as illustrated inFIGS.18and19). The movable segment may then be moved out of position to allow the shell102to release form the die press130and the dies132and/or134. It should also be noted that the ends142of a shell formed from a pre-consolidated cellulosic mat may be rough after manufacturing, and the ends142may be trimmed (e.g., machined, milled) after the shell102has been formed in the die press130. However, a pre-consolidated cellulosic mat is provided by way of example and is not meant to limit the present disclosure. In other embodiments, a pre-formed planar fiber board may also be molded to form a composite material shell102. For instance, an MDF board may be heat treated to its softening point and then deformed in a press. In some embodiments, a shell102may also be corrugated (e.g., in the manner of cardboard). When the shell102is formed (e.g., using a wet process, a wet-dry process, a dry process, a fiber hoard process, or another process), various surface features and/or contours can be formed in the shell102using various mold or press features. For example, a shell102having a thickness of about one-eighth of an inch (⅛″) can be formed and textured using a mold or press with a complementary relief pattern that forms a wood grain pattern on one or more surfaces of the shell102. Additionally, a shell102can be formed of more than one molded or pressed composite material segment joined together (e.g., using an adhesive binder or another adhesive at contact points along mating surfaces of the shell segments). Further, in some embodiments, a shell102can be formed using another process, such as extrusion. For example, the shell102may be formed using one or more extruded plastic materials, vinyl materials, polyvinyl chloride (PVC) materials, fiber glass materials, and so forth. In a similar manner to a molded material that forms a composite shell102, various surface features and/or contours may be formed in an extruded shell102(e.g., using various mold and/or press features). Once the shell102has been formed under high temperature and pressure, a number of different surface finishes and/or treatments may be applied to the shell102. For example, one or more layers of primer, paint, and/or stain can be applied to the surface of the shell102. An interior door jamb assembly100may be sold as a primed and ready-to-paint unit. In some embodiments, a veneer, such as a wood veneer, may also be applied to one or more surfaces of the shell102. The shell102may be glued (e.g., using an adhesive binder or another adhesive) to the core104. The core104can be formed of a wood material (e.g., scrap wood), a composite material (e.g., particle board (PB), MDF, plywood, laminated veneer lumber (LVL), wafer board, finger-jointed wood, and so forth) having a generally rectangular cross-sectional area. For example, the core104can be cut to fit and then glued in behind the shell102. It should be noted that because the cavity of the outer shell102hides the inner core104, the core104may be rough and/or unfinished (e.g., not finely milled). For instance, the core104can be formed from edge glued blocks, finger jointed blocks (e.g., as described with reference toFIGS.5and6), and so forth. In some embodiments, the core104can be made of particle board and/or MDF (e.g., as described with reference toFIG.7). In some embodiments, the core104can be made of a laminated lumber, such as plywood (e.g., as described with reference toFIGS.10-21). Further, in some embodiments, reinforcing blocks of a different material (e.g., milled lumber) can be positioned proximate to key areas of the jamb116(e.g., behind the hinges108as described with reference toFIG.6). For example, MDF may have better screw holding ability compared to, for example, particle board, and MDF may be used behind hinges108while particle board or another less expensive material is used for the remainder of the core104. In another example, plywood, LVL, or wafer board may have better screw holding ability and/or moisture resistance compared to particle board and MDF, and one or more of these materials (e.g., plywood, LVL, wafer board) may be used behind hinges108while particle board, MDF, and/or another less expensive material is used for the remainder of the core104. LVL, finger-jointed wood and/or other materials that exhibit dimensional stability may also be desirable for strategic positioning along the core104. The techniques and apparatus of the present disclosure may provide for improved raw material utilization. For example, wood residuals, particle board, and/or MDF segments used for the inner core104may be milled from smaller sections of wood into the shape of the cavity in the outer shell102(e.g., as opposed to typical door jambs and stops, which are milled from larger sections of wood). Further, in embodiments where the inner core104has a generally rectangular cross-sectional profile, the core104may be cut from a standard thickness flat panel by sawing rather than by milling larger wood sections using, for instance, a molder. It should also be noted that forming the outer shell102from a slurry and/or a pressed panel may save approximately twenty percent (20%) in material (e.g., in comparison to milling the jambs and stops from larger sections of wood). The outer shell102can be made from wood fiber and can include small trees that would otherwise be too small to process into typical jambs and stops, as well as including branches, knots, and small and/or short wood scraps. Further, the composite shell102can be made from tree species not typically used in the manufacturing of door jambs (e.g., due to stability issues, size, abundance, and/or other factors). Additionally, it is noted that typical door stops are nailed or stapled into the face of a door jamb through the face of the stop. The holes are then filled prior to finishing (e.g., painting) the door jamb. However, in accordance with the present disclosure, there are not necessarily holes through the stop118that are filled. Further, as opposed to door jambs with a stop nailed to the jamb, there is also not a gap or a seam between the jamb116and the stop118, which would otherwise be caulked prior to finishing (e.g., painting) the jamb. However, a door jamb assembly100with a seamless stop118is provided by way of example and is not meant to limit the present disclosure. In some embodiments, a door jamb assembly100may be formed with a flat jamb116, and an additional stop118may be nailed onto the jamb116(e.g., as described with reference toFIGS.25and26). It should also be noted that the surface of a molded door jamb assembly100can be matched to the surface of, for example, a molded 6-panel door (e.g., having an MDF exterior). For instance, a door jamb assembly100can have a primer coat applied, which may be similar or comparable to the door mating to the door jamb assembly100. The door jamb assembly100can also have a surface texture126, such as an embossed wood grain pattern (e.g., as described with reference toFIG.8) or another surface texture126(e.g., as described with reference toFIG.9), similar to or comparable to the door mating to the door jamb assembly100. Additionally, wood product defects in the exterior of the door jamb assembly100, such as splits, tear outs, knots, pitch bleeds, resin bleeds, and the like may be reduced or eliminated using the systems, techniques, and apparatus disclosed herein. Furthermore, the incidence of typical wood distortion found in existing wood products, e.g., cupping, warping, twisting, crooking, and so forth, may be reduced or eliminated, e.g., due to the shape of the composite outer shell102, which can stabilize the inner core104. Further, in some embodiments, a core104may include structural features configured to further strengthen a door jamb assembly100and/or reduce or minimize dimensional distortion/cupping. For example, one or more features, such as longitudinal channels and/or grooves124may be formed in the core104(e.g., on a back side of the core as described with reference toFIG.30). In some embodiments, the grooves124may run the length of the core104. Additionally, improved utilization of wood and/or reduction of material waste of wood over typical manufacturing may be achieved using the systems, techniques, and apparatus disclosed herein. Also, areas with an abundant wood fiber supply but a lesser supply of larger sections of wood for milling one-piece jamb parts can benefit from the ability to locally manufacture the door jamb assemblies100disclosed herein, incurring, for example, reduced shipping costs due to domestic production. It should also be noted that the defect rate may be reduced (e.g., in comparison to milling wood components) as described herein. In some embodiments, the edges and/or sides of a door jamb assembly100may be hack beveled (e.g., as described with reference toFIGS.16and17and34), square (e.g., as described with reference toFIGS.12and13), trim guide (e.g., as described with reference toFIGS.18through21and35), and so forth. Further, the width of a door jamb assembly100can vary based upon, for instance, door opening size, wall thickness, and so forth. The shape of the stop118may also vary. For example, with reference toFIGS.20and21, the stop118may be colonial shaped. With reference toFIGS.12and13, the stop118may also have square edges. However, these shapes are provided by way of example and are not meant to limit the present disclosure. In other embodiments, a stop118may have a different shape, including, but not necessarily limited to: a one-radius edge (e.g., as described with reference toFIGS.14and15), a two-radius edge (e.g., as described with reference toFIGS.10and11), and so forth. The width and/or height of a stop118may also vary. Further, the door jamb assembly100may have different end work, including, but not necessarily limited to: a straight cut (e.g., as described with reference toFIG.22), a miter cut (e.g., as described with reference toFIG.23), a coped end cut (e.g., as described with reference toFIG.24), and so forth. In some embodiments, the thickness of the outer shell102can be at least approximately the thickness of a hinge108. During assembly (e.g., of a door jamb set), the shell102can be routed through to expose the inner core104, and the hinge108can be attached to the door jamb using fasteners (e.g., screws110) connected to the inner core104. However, routing through a door jamb assembly100during assembly is provided by way of example and is not meant to limit the present disclosure. In other embodiments, a door jamb assembly100may be machined/finished (e.g., for hinges108) prior to sale and/or assembly as a door jamb set. The door jamb set formed of the door jamb assemblies100can include the door106, and the pre-hung door can be attached to the door opening by fastening (e.g., nailing or screwing) through the flat of the jamb, i.e., through the outer shell102, through the inner core104, and into the door rough opening. In some embodiments, the stop118can be hollow (e.g., as described with reference toFIGS.10,12,14,16,18, and20). The interior cavity of the hollow stop118can be left empty, or, in some embodiments, a protrusion120of the core104can extend into the cavity of the stop118(e.g., again as described optionally with reference toFIGS.10,12,14,16,18, and20). For example, an additional piece of wood, additional wood fragments, or another material can be glued or otherwise fastened to the rough and/or unfinished (e.g., not finely milled) edge glued blocks, finger jointed blocks, particle board, and/or MDF forming the core104. Such additional wood or other material disposed in the cavity of the stop118may form, for example, a door stop core. However, in other embodiments, the stop118may be solid (e.g., as described with reference toFIGS.11,13,15,17,19, and21). For example, when the shell102is molded from slurry and/or pressed from a flat composite panel, the stop118can be formed from a portion of the slurry and/or pressed panel which is less compressed than the remainder of the shell102. In some embodiments, the stop118can be formed from a loose mat and binding agent/resin/wax arrangement, where the raw material mat thickness is increased in the area of the stop118. Further, in some embodiments, the stop118can include interior strengthening/stabilizing features122, including, but not necessarily limited to: latticing, honeycombing, cross-bracing, and so forth (e.g., as described with reference toFIGS.27through29). These features122may also be formed of slurry or panel material that is less compressed than the remainder of the shell102. Further, such features122may be formed of separate material glued or otherwise attached to the shell102. In some embodiments, the interior of the stop118may also be corrugated (e.g., in the manner of cardboard). While the description herein has detailed door jamb assemblies100including jambs116and stops118for interior doorway applications with some specificity, it is noted that these particular trim molding applications are provided by way of example and are not meant to limit the present disclosure. In other embodiments, the systems, techniques, and apparatus described herein can be used for various other interior trim molding applications, including, but not necessarily limited to, interior millwork applications that can use a molded outer surface shell with a rough wood stiffener inside, such as base moldings, case moldings, crown moldings, etc. Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims. | 25,194 |
11859437 | DETAILED DESCRIPTION In the following pages, numerous specific details are set forth to provide a thorough understanding of the concepts underlying the described embodiments. It will be apparent, however, to one skilled in the art that the described embodiments may be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order to avoid unnecessarily obscuring the underlying concepts. In the Detailed Description, reference is made to the accompanying drawings, which form a part hereof, and in which are shown by way of illustration specific embodiments in which the invention may be practiced. It should be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention. For example, a specific type of window is shown in the Detailed Description and it should be understood that various embodiments of the invention can be used on any type of window, door, or the like that is fitted to an opening in a structure. The various embodiments described here provide many advantages, some of which are mentioned here. The advantages include forming a mechanical barrier to water proofing, easier means for installing windows, doors and the like. The method and apparatus would eliminate a lot of waste in window replacement, reduce or eliminate the need for much of the flashing materials used to install windows today, which leads to less cost and more efficient window replacement or placement in new construction. Adhesive backing on either or both of the male and female components can replace flashing and other water proofing materials, for example. Being able to replace or install windows without the use of a ladder significantly increases the safety of the job site. Window placement would be more uniform when the window attachment system is employed. The exterior of theFIG.1is an elevational view of an exterior portion150of an out-swinging window system100according to one embodiment. The out-swinging window system100shown is a casement window. A casement window is one type of out-swinging window system. The casement window shown and described is an example of a window that includes the invention. It should be noted that the invention is not limited to a casement type window and can be used on all windows, doors, sliding doors, and the like. In other words, the invention could be used on anything which is installed into an opening in a building. The casement window units shown inFIG.1includes a rectangularly shaped window frame111including a (first) vertical frame member131, a (second) vertical frame member124, a horizontal upper frame member113, and a horizontal lower frame member114. The out-swinging window system100includes a casement window sash117which includes an upper horizontal member118, a lower horizontal frame member119spaced apart vertical frame members120and a transparent glass panel121. The casement sash117is provided with upper and lower track and hinge assemblies122which movably mount the case window sash117to the window frame111. The horizontal lower frame member114is slanted outwardly, thereby forming a sill130on the exterior surface150of the casement window or out-swinging window unit100. It should be noted that the frame members113,114,131and124are also referred to as jambs. Attached to the frame members113,114,131and124is a male portion1010of a window attachment system1000. As will be explained more fully later, the window attachment system1000also includes a female portion1040which ultimately is attached to the edges of a similarly sized opening in the building for the window system100. As mentioned earlier, the window attachment system can be used on other types of windows, doors, sliding glass doors or even appliances that are fitted to window-type openings in a house or other type of building. FIG.2is an elevational view of an exterior portion of an out-swinging window system with both the male portion1010and the female portion1040of the window attachment system1000placed on the frame members113,114,131and124of the casement window system100. The male portion1010would be permanently attached to the frame members113,114,131and124. The female portion1040of the window attachment system1000is engaged with the male portion1010. In an alternative embodiment, the male portion and female portions are reversed in the system. The female portion1040ultimately is attached to the inside of the opening as installed in a building. Shown inFIG.2is one option for packaging of a new casement window system100that employs the window attachment system11000discussed herein. The female portion1040is shipped with the window100so that a person installing the new window100has both the male portion1010and the female portion1040when the window is received. Of course, in another embodiment for a new window100, the window100can be shipped as shown inFIG.1with only the male portion1010attached to the frame members113,114,131and124of the casement window system100. In this embodiment, the female portion1040can be shipped separately or disengaged from the male portion1010. FIG.3is a cross-sectional view of the window system100shown inFIG.1along line3-3. In this particular cross-sectional view, the vertical frame member124is not shown for the sake of clarity. As shown inFIG.3, the window system100includes the upper horizontal frame jamb113and the lower horizontal frame member114. The upper horizontal frame member113includes a weather seal or rain cap213. The lower horizontal frame member or jamb114includes the exterior sill surface130as well as an interior sill surface214. The window system100shows a lower horizontal sash unit119and the upper horizontal sash unit118. Positioned within the sash is a transparent glass panel121. The transparent glass panel121is a double pane, thermal pane type of glass unit in which the pane of glass is actually comprised of two panes of glass which are sealed. It should be noted that a transparent pane of glass can include a single pane of glass, a double pane of glass or triple pane of glass. As shown inFIG.3, the window system is in a closed position where the sash118,119is brought into engagement with a weather-strip313associated with the upper horizontal frame member and a weather-strip314associated with the lower horizontal frame member114. When the sash118,119is engaged with the weather-strip313,314, a seal is formed between the frame113,114and the sash118,119. Additional seals318,319are used to seal the portion of the sash118,119from weather which would occur at the exterior surface150of the window system100. The male portion1010of the window attachment system1000is attached to the exterior surface of the window frame. As shown inFIG.3, the male portion is shown in cross-section at the upper horizontal frame member113and at the exterior sill surface130. The male portion1010of the window attachment system1000wraps entirely around the exterior surface of the window100frame, in one embodiment. In other embodiments, it wraps partially around the exterior surface, such as 75%. It is located at a fixed distance from either the front of window100frame or the back of the window100frame so that it can engage the female portion1040which is located around the interior of a rough opening for the window100. As shown inFIG.3, the lower horizontal frame member114or jamb is provided with an essentially L-shaped wood cover316. The L-shaped wood cover316attached to the lower horizontal frame member or jamb114can be thought of as an extension of the lower horizontal frame portion or jamb114. The L-shaped wood cover316houses some of the hardware associated with operating the window system100. The operating hardware is not shown for the sake of clarity. The use of such components eliminates the need for a nail fin or flange for example. FIG.4shows a diagrammatic cross-sectional representation of the window attachment system100, according to an example embodiment. The window attachment system100is for securely attaching a window100to a wall510of a structure500, such as a residential home or commercial building or the like. The wall510has an opening520therein. The opening is many times referred to as a rough opening in the construction trade. Homes and commercial buildings employ balloon construction. The wall is framed from a polarity of studs512. The studs512are provided with sheathing514such as oriented strand board (“OSB”). OSB is twice as strong in sheer as plywood. OSB provides rigidity and encloses the wall along the exterior of the wall. The sheathing is covered with cladding (such as siding or the like) later in the construction process. The studs512can be made of metal or wood. Metal is generally used in commercial building and wood is generally used for residential building. The wall500is insulated, wired and plumbed and then enclosed with a drywall plaster board or drywall516. A rough opening520is generally formed during construction. Once the wall is generally provided with OSB or sheathing514, the windows100are installed to enclose the structure. The female portion1040is placed in the rough opening520. The female portion1040is attached to or integrated with an L-shaped bracket1042in the version for new construction which is shown inFIG.4. The L-shaped bracket1042may not be necessary in replacing existing windows, for example. A finger1044or other attachment feature is attached to or integrated with the L-shaped bracket1042and forms a channel1046into which the male portion1010connects. The female portion1040is placed at the corner of the rough opening and the exterior surface of the wall500. The female portion1040is continuous or substantially continuous around the rough opening520which forms a continuous channel1046about the rough opening520. The male portion1010is also continuous or substantially continuous around the exterior surface of the window100. To attach the window100into the rough opening520, the window100is placed to the wall500at the rough opening520. The male portion1010will then be approximately aligned with the channel1046. The window is then pressed into place where the male portion1010fully or substantially fully engages the channel1046of the female portion1040. The finger1044of the female portion is somewhat flexible so as to flex as the male portion1010is inserted into the channel1046. As shown inFIG.4, the male portion1010is monolithic or integral to the window frame. The female portion1040could be made of any sufficiently flexible material, such as extruded vinyl or fiberglass, or the like. In another embodiment, the female portion1040could be made of C&C aluminum. Similarly, the male portion1010can be made of a sufficiently flexible material, such as extruded vinyl or fiberglass, C&C aluminum or the like. As shown, the male portion is on the window100frame and the female portion1040is on the wall500and specifically at the rough opening520of the wall500. It is contemplated that the female portion1040could be placed on the window and the male portion could be placed at the rough opening520on the wall500, in another embodiment. FIG.5shows another embodiment of a male portion1110of the window attachment system1000as it is attached to the window100frame, according to an example embodiment. In this embodiment, the male portion1110includes a substantially straight backer1112. A male finger1114is attached to the backer1112on one side of the backer1112. Attached to the other side of the backer1112is a fastener1116. The fastener1116is used to attach the straight backer1112to the frame of the window100. The straight backer1112abuts the exterior surface of the window100frame. Even though only a portion of the window100and the window100frame is shown inFIG.5, it should be understood that the male portion1110is attached on all sides of the window1110frame. In some embodiments, the window100frame can be provided with a groove102therein for receiving the fastener1116of the alternate male portion1110. The groove102could also be used to correctly position the male portion1110. FIG.6shows the female portion1040′ in place on an existing wall600, according to another example embodiment. In this embodiment, the L-shaped bracket1042′ is attached to the wall so that one portion abuts the cladding614on the exterior surface of the wall. This represents a retrofit application where the cladding on the existing wall is not removed or cannot be removed easily. In this embodiment, the female portion1040′ is attached to the rough opening after the old window has been removed. In one embodiment, the female L-shaped bracket1040′ will have a shortened leg where it abuts the cladding. In another embodiment, the leg for abutting the exterior portion of the wall near the rough opening will be eliminated. It is contemplated that the female portion1040may not come as one piece but may be shipped as multiple pieces that need to be attached and formed in the rough opening on site. The retrofit version of the female portion1040′ may have to be made of more flexible material than the version used for new construction, shown inFIGS.2and4. FIG.7is a cross-sectional view of the window100installed in the rough opening of the wall, according to an example embodiment. The male portion1010of the window attachment assembly1000is shown engaged with the female portion1040of the window attachment assembly1000. The male portion, as shown inFIG.7, is attached to one of the outer perimeter of the window100frame. The female is attached to the inner perimeter of the opening in the building. The male portion is engaged with the female portion when the window is placed into the opening. The male portion includes an enlarged end. The female portion includes a flexible clip that allows the enlarged end to pass the clip. The female portion is also shaped to have a pocket for receiving the enlarged end of the male portion. In one embodiment, the male portion or female portion attached to the outer perimeter of the window is formed integrally with the window. In one embodiment, a fastener is used to attach the male portion or female portion the outer perimeter of the window. In still another embodiment, the male portion or female portion attached to the outer perimeter of the window is continuous. It forms a continuous channel or male portion that enhances the weatherproof aspect of the installed product. In another embodiment, the other of male portion or female portion attached to the inner perimeter of the opening in the building is continuous. The other of the male portion or female portion attached to the inner perimeter of the opening includes an L-shaped base, in one embodiment. The L-shaped base having the other of the male portion or female portion is attached to one leg of the L-shaped base. The other leg is formed to abut an exterior surface of the wall having the opening therein. The other leg also acts to properly space the other of the male portion or the female portion. In another embodiment, the other of the male portion or female portion attached to the inner perimeter of the opening includes a substantially straight base. The other of the male portion or female portion attached to the straight base. In yet another embodiment, the other of the male portion or female portion attached to the inner perimeter of the opening is comprised of a plurality of sections. The sections are assembled and attached to the inner perimeter of the window. In still another embodiment, the window includes weather proofing material. The weather proofing material covers the male portion in the state where it is engaged with the female portion. In other words, it is in the space between the window and the rough opening of the wall into which the window is installed. The weather proofing material includes a backer rod and a caulking material. A window attachment system for attaching a window to an opening in a building includes a male portion and a female portion. One of the male portion and the female portion is attached to one of the outer perimeter of the window frame or the inner perimeter of the opening in the building. The other of the male portion and the female portion is attached to the outer perimeter of the window frame or the inner perimeter of the opening or rough opening520in the building. The male portion1010is substantially fully engaged with the female portion1040when the window100is placed or properly set into the opening520. The male portion1010includes an elongated arm1012attached to a shoulder portion1014. The elongated arm1012includes an enlarged end1016. The female portion1040includes a flexible clip1046that allows the enlarged end1016to pass the clip1046. The female portion1040also features a short beam1044which attaches the clip1046to a base portion1050. The clip1046and the short beam1044of the female portion1040form a pocket1047for receiving the enlarged end1016of the male portion. The clip1046includes a slight inward bend along the length of the clip1046resulting in the pocket1047near the short beam1044. In this embodiment the male portion is formed integrally with the window100. In another embodiment shown inFIG.5, a fastener is used to attach the male portion1010to the outer perimeter of the window100. Although a simple cross section view is shown, it is to be understood that the male portion1010attached to the outer perimeter of the window1010is continuous. The female portion as attached to the inner perimeter of the opening520in the building500is also continuous. The continuous female portion1040forms a continuous channel into which the continuous male portion1010fits. The continuous of the female portion1040and the male portion1010enhances the weatherproof aspect of the installed product. The female portion1040is attached to the inner perimeter of the opening and includes an L-shaped base1050. The L-shaped base1050has a first leg1052to which the short beam1044and clip1046are attached. The other leg or second leg1054is formed to abut an exterior surface of the wall500having the opening520therein. The leg1054acts to properly space the the female portion. As shown inFIG.7the leg1054is abutting the sheathing514of the wall500. In another embodiment, the female portion1040attached to the inner perimeter of the opening520includes a substantially straight base. The leg1054is eliminated. This base is referred to as the straight base and is shown inFIG.6. In another embodiment, the male portion1010or female portion1040are comprised of a plurality of sections. The sections are assembled on site to form a substantially continuous channel. The window is held in place by the clip1046and the leg1014and attached to the inner perimeter of the window. The window can be separated from the wall or disengaged from the wall using a siding puller. In another embodiment, the male portion1010and the female portion1040can be switched. FIG.8is a cross-sectional view of the window100installed in the rough opening520of the wall500and weather sealed, according to an example embodiment. When the male portion1010is engage with the female portion1040, a substantially weather tight fit is formed. As shown inFIG.8this seal is further enhanced by placing a backer rod800into the space between the rough opening520in the wall and the window100frame. This is further covered by a liberal bead of caulk810to further enhance the weather seal. The backer rod800and the caulk810provide insulative properties as well. As shown inFIG.8, the back side of the window attachment system is provided with spray foam insulation820to further insulate the installed window from the outside elements. FIG.9is a flow diagram of a method1200for installing a window provided with the male portion and the female portion, according to an example embodiment. The method1200of attaching a window to an opening in a building includes providing a window frame with one of a male portion or a female portion of a window attachment system1210, and attaching the other of a male portion or a female portion of a window attachment system to the opening in a building1212. The window is then positioned to align the male portion and the female portion of the window attachment system1214. A force sufficient to engage the male portion with the female portion is then applied to attach the window to the building. The method1200of attaching a window further includes weatherproofing the gap between the window and the opening in the building1218. Several embodiments are set forth in the above specification and described drawings. These embodiments include: A window attachment system for attaching a window to an opening in a building includes a male portion and a female portion. One of the male portion and the female portion is attached to one of the outer perimeter of the window frame or the inner perimeter of the opening in the building. The other of the male portion and the female portion is attached to the outer perimeter of the window frame or the inner perimeter of the opening in the building. The male portion is engaged with the female portion when the window is placed into the opening. The male portion includes an enlarged end. The female portion includes a flexible clip that allows the enlarged end to pass the clip. The female portion is also shaped to have a pocket for receiving the enlarged end of the male portion. In one embodiment, the male portion or female portion attached to the outer perimeter of the window is formed integrally with the window. In one embodiment, a fastener is used to attach the male portion or female portion the outer perimeter of the window. In still another embodiment, the male portion or female portion attached to the outer perimeter of the window is continuous. It forms a continuous channel or male portion that enhances the weatherproof aspect of the installed product. In another embodiment, the other of male portion or female portion attached to the inner perimeter of the opening in the building is continuous. The other of the male portion or female portion attached to the inner perimeter of the opening includes an L-shaped base, in one embodiment. The L-shaped base having the other of the male portion or female portion is attached to one leg of the L-shaped base. The other leg is formed to abut an exterior surface of the wall having the opening therein. The other leg also acts to properly space the other of the male portion or the female portion. In another embodiment, the other of the male portion or female portion attached to the inner perimeter of the opening includes a substantially straight base. The other of the male portion or female portion attached to the straight base. In yet another embodiment, the other of the male portion or female portion attached to the inner perimeter of the opening is comprised of a plurality of sections. The sections are assembled and attached to the inner perimeter of the window. In still another embodiment, the window includes weather proofing material. The weather proofing material covers the male portion in the state where it is engaged with the female portion. In other words, it is in the space between the window and the rough opening of the wall into which the window is installed. The weather proofing material includes a backer rod and a caulking material. A window kit includes a window having an outer frame, and one of a male portion or a female portion of an attachment system attached to the frame of the window. The window kit can also include the other of the male portion or the female portion. In one embodiment, the other of the male portion or the female portion is continuous. In another embodiment, the other of the male portion or the female portion is formed of multiple parts. In still a further embodiment, the other of the male portion or the female portion attached to the one of the male portion or the female portion of the window. A method of attaching a window to an opening in a building includes providing a window frame with one of a male portion or a female portion of a window attachment system, and attaching the other of a male portion or a female portion of a window attachment system to the opening in a building. The window is then positioned to align the male portion and the female portion of the window attachment system. A force sufficient to engage the male portion with the female portion is then aligned to attach the window to the building. The method of attaching a window further includes weatherproofing the gap between the window and the opening in the building. The various embodiments would provide many advantages, some of which are mentioned here. The advantages include forming a mechanical barrier to water proofing, easier means for installing windows, doors and the like. The method and apparatus would eliminate a lot of waste in window replacement, reduce or eliminate the need for much of the flashing materials used to install windows today, which leads to less cost and more efficient window replacement or placement in new construction. Window placement would be more uniform when the window attachment system is employed. The window could be snapped into place and removed using a common tool such as a siding puller. These and other advantages stem from the above described and shown embodiments. While the embodiments have been described in terms of several particular embodiments, there are alterations, permutations, and equivalents, which fall within the scope of these general concepts. It should also be noted that there are many alternative ways of implementing the various apparatuses and methods of the present embodiments. It is therefore intended that the following appended claims be interpreted as including all such alterations, permutations, and equivalents as fall within the true spirit and scope of the described embodiments. | 26,011 |
11859438 | DETAILED DESCRIPTION OF THE INVENTION While the subsequent description is in relation to windows or doors having a glazing bead to secure a glazing unit, typically a sheet of glass, the application of the present invention is not limited to windows and doors, but to any such system having a glazing unit secured by a glazing bead. FIGS.1A &1Billustrate prior art frame systems.FIGS.1A and1Beach illustrate a frame system1having a frame2and a bead4which act to compress glazing6between a wedge gasket10and a flipper gasket12. The bead4is shown secured to the frame2on the inside16of a space by two mechanical snap-fit joints. The frame system1is also shown incorporating a thermal break20to improve the thermal efficiency of the frame system1. The thermal break spaces the two halves of the frame member2and traps a pocket of air within the frame2to reduce the thermal conductivity of the frame2. Outer frame gaskets14are also shown secured to the frame2ofFIG.1Ato provide a watertight seal around the frame2. FIG.2illustrates a cross-sectional view of a frame system100. The bead104is shown as having an “L-shaped” body having first112and second118ends and a clip200secured to the body. The bead104is secured to the frame102at the first end112of the body and at a first end206of the clip200. When the bead104is secured to the frame102, opposed seals106a,106bapply a compressive force against a glazing unit6which acts to secure the glazing unit6in the frame system100. The frame102is also shown having a thermal break20, which enhances the thermal efficiency of the frame system100. The subsequent description of the bead104will refer to features illustrated both inFIGS.2and3. The bead104is secured to the frame102by first108and second110connections. As shown inFIGS.2and3, the first connection108is formed by the first end112of the bead104engaging with a corresponding first end114of the frame102. The second connection110is formed between the first end206of the clip200and a corresponding second end116of the frame102. The first108and second110connections are formed as respective first and second mechanical snap-fit joints, where the first114end of the frame102and first end112of the bead104form complementary parts of the snap-fit joint of the first connection108and the second116end of the frame102and first end206of the clip200form complementary parts of the snap-fit joint of the second connection110. The snap-fit joint of the first connection108is formed by the first end114of the frame102having a nub coupling with a corresponding nub on the first end112of the bead104to prevent the corresponding ends112,114being pulled apart. The second connection110is formed by the first end206of the clip200having a nub coupling with a corresponding nub on the second end116of the frame102to prevent the corresponding ends206,116being pulled apart. Together, the first and second connections secure the bead104to the frame102. While a specific configuration of snap-fit joints have been illustrated here, it would be apparent that other releasable joints or configurations of the first108and/or second110connections would be included by this description. The bead104also has a second end118having a seal106aattached thereto. Seal106ais opposed to seal106b, which in combination apply a compressive force to the glazing unit6to secure the glazing unit6in place when the bead104is secured to the frame102. The clip200is also shown having a base202which is secured to the bead104. The base202may be secured to the bead104by any of a mechanical or chemical joint. For example, the base202may be pressed into a slot or cavity defined within the body of the bead104and/or glued or otherwise adhered to the bead104to provide a rigid fixation between the base202and the body of the bead104. The clip200may be secured by crimping or rolling into a corresponding section of the bead104. The clip200may be secured by an interference fit with the corresponding section of the bead104. The clip200may be secured by inserting into one or more corresponding slots or members (not shown) within the bead and turned to secure the clip200in position. The clip200is shown having a first finger204extending from the base202to the first end206in a first direction, and a second finger208extending from the first finger204to a free distal end210in a second direction. While the second finger208is shown extending from the first finger204approximately mid-way along the first finger204, it would be understood that the second finger208may extend from other locations along the first finger204to achieve some of the advantages of the present invention. Further, while the second finger208extends in a direction substantially perpendicular to the first finger204, it would be understood that the second finger208may extend in other directions with respect to the first finger204while retaining the benefits of the present invention. Preferably, the second finger208extends in a perpendicular direction to the first finger204from a point approximately mid-way along the first finger204. The second finger208is also illustrated as an arcuate structure which curves towards the second end118of the bead104. However, other shapes and configurations of the second finger208are possible, for example, one or more straight sections may be used to obtain the benefits of the present invention. The second finger208is also shown extending between a gap120formed by the second end118of the bead104being spaced from the second end116of the frame102. The second finger208has a width that tapers from its connection to the first finger204to its distal end210. The width at the connection between the first204and second208fingers is greater than the width at the distal end210. Having a tapered second finger208allows the distal end210to rest against the glazing unit6without movement of the glazing unit within the assembled frame100releasing the clip200. While the bead104will have a length sufficient to cover the section of frame102it will be secured to, it is not essential for the clip200to have a length equal to the bead104. For example, the clip200may be implemented as one single clip200extending the length of the bead104, or only extending for a proportion of the bead104. In some cases, the length of the clip200may be equal to the length of the bead. In some cases, the clip may be 10 mm in length. The clip200may have a length between 10 mm and 1000 mm. While specific lengths are provided here as examples, it would be apparent that the clip200may have any length as the clip will be suitable for a wide range of frame systems100which are suitable for different applications. The frame system100may utilise a plurality of clips200distributed along the length of the frame102. The clip200is preferably made from plastic, but it would be understood that other deformable materials would provide suitable alternatives. This would provide a base202with the necessary stiffness to remain secured in the body of the bead104, but also provide first204and second208fingers with the requisite flexibility to deflect under load to release the bead104from the frame102. Further, by having a deformable clip200, the bead104can apply a compressive force against the glazing unit6without the need for an additional wedge gasket10. The clip200may be made from one or more different materials such as plastic. The clip200may be made from a polyamide. In some cases, the clip200comprises nylon. Nylon is particularly advantageous, due to its combination of strength, extrusion accuracy and stability. Making the clip from plastic also allows for detailing, such as a barbed end, to be included. This provides a clip with functionality that would otherwise not be possible using a stiffer material such as aluminium, as an aluminium clip would yield when deformed to the same degree. While specific materials have been provided as examples, it would be apparent that other materials having suitable material properties would also be suitable. In some cases, the clip200has a tensile strength between 40 to 90 MPa. In some cases, the clip200has a tensile modulus from 2 to 4 GPa. The body of the bead104may be made from any of aluminium, PVC or wood. The bead104may be between 15 mm×15 mm and 50 mm×50 mm. The bead104may be larger than 50 mm×50 mm. While a bead104having a square cross-section has been illustrated in the Figures, it would be apparent that a square cross-section is given by way of example and that the bead104need not have a square cross-section. The bead104may have a circular, rounded, rectangular or otherwise shaped cross-section depending on the particular aesthetic requirements of the frame system100. One of the advantages of the present system100is the ease with which the bead104can be removed from the frame102in a manner which also reduces the risk of damaging the frame102or the bead104.FIG.4illustrates how an external tool300can be used to remove the bead104from the frame102, for example when the glazing unit6becomes damaged. Using an external tool300having a base302and an elongate portion304, an installer is able to pass the elongate portion304between the glazing unit6and the seal106ato engage the distal end210of the second finger208. Once engaged, an installer is able to push the tool300against the distal end210and apply a force to the second finger208. This force applies a force to the first finger204, which in turn causes the first finger204to deform. As the first finger204deforms, the first end206of the first finger204moves relative to the second end116of the frame102. The movement of the second finger208causes the first end206of the first finger204to disengage from the second end110of the frame102, releasing the second connection110. The first finger204may extend into a recess109in the frame102. The recess109may also include an inclined surface109aconfigured to urge the first finger204away from the frame102as it is deflected by the tool300. To be able to pass between the seal106aand the glazing unit6when the glazing unit6is secured to the frame102and apply a force to the second finger208, the elongate portion304must be sufficiently thin, but stiff to achieve this. An installer is able to manually apply the force to release the second connection110by simply pressing down onto the second finger208, which greatly improves the speed and ease of disassembly of the frame system100. The tool300is typically be between 0.5 mm and 1.0 mm thick. The tool300is preferably made from steel, but may also be made from plastics, glass-fibre reinforced plastic, or other metals. The extension304may be between 50 mm and 500 mm long. It should be noted, that in some cases, the installer will not have to manually release all of the second connections110to release the bead104from the frame. For example, when one long clip200made is used, after a sufficient length of the clip is released, the installer will be able to rotate the bead104free without damaging the clip200, as the flexibility and geometry of first end206and second end116will cause the second connection110to release without having to engage the second finger208with the clip is released, the installer will be able to rotate the bead104free without damaging the clip200, as the flexibility and geometry of first end206and second end116will cause the second connection110to release without having to engage the second finger208with the tool300. The recess109is also designed to extend as little as possible into the frame102so that the clip200does not interfere with any other mechanisms, such as handles and locks, that may be present in the frame102, while remaining aesthetically pleasing. While the tool300has been described as pressing directly down onto the distal end of the second finger210, it would be apparent this was not essential and one or more other materials may be disposed between the elongate portion304and the distal end210to release the clip200. While the Figures illustrate one example of a clip200that is released by pushing the tool300to engage the distal end210of the second finger208, it would be understood that a pulling force could be applied by the installer to release the bead104. One way of achieving this would be to extend the first finger204between the second end116of the frame member102and have the nub on the first end206of the first finger204pointing away from the glazing unit6and having the nub on the second end116of the frame member102pointing towards the glazing unit6, so that the second connection110is reversed from that shown inFIGS.2and3. This would allow the installer to insert the tool300to engage the distal end210and apply a tensile force on the distal end210to deflect the first finger204away from the second end116, thereby releasing the second connection110and allowing the bead104to be released from the frame102. Once sufficient force has been applied to the distal end210, the first end206of the first finger204will be sufficiently displaced with respect to the second end116of the frame102and release the second connection110. The installer may keep pressing the tool onto the second finger208to further deflect the clip200such that the first end206of the first finger204is spaced from the second end116of the frame102, thus providing additional clearance to release the bead104from the frame102. The installer may then remove the damaged glazing unit6from the frame system100, as the bead106is no longer applying a compressive force to the glazing unit6. In examples, the distal end210of the second finger208may rest against the glazing unit6when the bead104is secured to the frame102. This will increase the likelihood of the elongate portion304contacting the distal end210of the second finger208when inserting the elongate portion304into space between the glazing unit6and the seal106a. While the Figures illustrate the movement of the first end206as a translation, it would be apparent that the first end206may rotate with respect to the second end116of the frame102to release the second connection110. Further, while the external tool300is described as applying a force to the second finger208, it would be apparent that the external tool300may apply a torque to the second finger208, which in turn could release the second connection110between the first end206of the first finger204and the second end116of the frame102. Once the second connection110has been released, only the first connection108remains, as illustrated inFIG.5. The bead104may then be rotated relative to the frame102, anti-clockwise as illustrated inFIG.5, to space the first end206of the first finger204from the second end of the frame102. This removes the reaction force holding the first connection108in place and allows for the separation of the bead104from the frame102(see alsoFIG.6). While the bead104of the present invention has advantages in relation to disassembling the frame system100, the present invention also has benefits in relation to the assembly of frame systems100. Where a seal106ais present on the second end118of bead104, the installation of the bead104is considerably simpler compared to prior art beads4. An installer simply couples the first end112of the bead104to the first end114of the frame102, to form the first connection108, and rotates the bead104towards the glazing unit6, to bring the first end206of the first finger204into contact with the second end116of the frame102. The installer then presses the bead104onto the frame102, which causes the first finger204to deflect, due to its elasticity, and move relative to the second end116of the frame, due to the complementary surfaces of the first end206of the first finger204and the second end116of the frame102. The installer keeps pressing down until the first end206of the first finger204couples with the second end116of the frame102and clips into place, forming the second connection110. This may be indicated by an audible clicking noise. This simple method secures the bead104to the frame102and applies a compressive force to hold the glazing unit6in place in the frame102without the need for an additional wedge gasket10. In an example illustrated inFIG.7, the bead104has a first end which connects to a first end of the frame102to provide the first connection108. The bead104also has a second end118having a first portion212aand a second portion212bwhich are configured to secure a gasket216extending along a length of the bead104in a longitudinal direction. A part of the second portion212bis also shown extending into the gasket216and interdigitating with a first pair of fingers218aextending from the gasket216. The illustrated example is particularly advantageous, as application of an external force to the gasket216translates the gasket216in a vertical direction away from the second end118, thus easily releasing the gasket216from the second portion216band displacing the second finger of the clip200. The clip200illustrated inFIG.7is configured in a similar manner to that illustrated inFIGS.2to6. The clip200has a body and a first finger extending from the body at a first end to a second end206. The second end206of the first finger engages with the second end116of the frame102to form a second connection between the bead104and the frame102. The first108and second connections secure the bead104to the frame102and cause the bead104to apply a preload to the glazing unit6, securing the glazing unit6in place. This arrangement is advantageous, as it is not necessary to secure an additional wedge gasket to the bead104to ensure sufficient pressure is applied to secure the glazing unit6in place. This not only reduces the installation time of the door or window, but also reduces the amount of material used. The clip200also includes a second finger extending from the first finger to a distal end210which is inserted into the gasket216. In the illustrated example, the second finger comprises a proximal portion extending from the first finger in a substantially perpendicular direction and a distal portion extending from the proximal portion in a further substantially perpendicular direction. In the illustrated example, a part of the distal portion including the distal end210interdigitates with a second pair of fingers218bextending from the gasket216and helps to secure the gasket216against the second portion212b. The distal end210is also shown spaced from the glazing unit. Therefore, when the installer presses onto the gasket216, releasing it from the second end118, the gasket216is translated in the direction of the force. In one example, the installer presses down onto the gasket216and causes the gasket216to slide away from the second end118of the body in the vertical direction. As the body of the bead104is rigid compared to the clip200, the clip200undergoes substantially all of the deformation due to the force applied by the installer. As shown inFIG.7, displacing the gasket216results in a force being applied to the second finger, and consequently the first finger. As the first finger is engaged with the second end116of the frame102, sufficient force needs to be applied to the gasket216in order to separate the first finger from the second end of the frame102. Once sufficient force is applied to the gasket216, the first finger releases from the frame102, and the bead104can be rolled off the frame102to separate the bead104from the frame102, thus providing the installer a simple and efficient way to remove a clip-on bead104from a frame member102. The installer may press down onto the gasket216using a hand tool (not shown). The hand tool is preferably configured to enable an installer to push the gasket216down and to engage with an end of the bead104, so as to release the clip200from the frame member102. Once the clip200is released, the bead104can, for example, be rolled away from the frame member102by pulling the tool up along the surface of the glazing unit6. In one example, the hand tool engages with the bead104by hooking onto the second end118of the bead104. While the first218aand second218bpair of fingers are illustrated extending in a direction substantially perpendicular to the longitudinal axis of the bead104, it would be apparent this was not essential. While the part of the second portion212bis illustrated as extending into the gasket216in a substantially vertical direction, it would be apparent this was not essential. While first212aand second212bportions are illustrated, it would be apparent this was not essential, and the gasket216could be secured using either of the first212aor second212bportions. While the distal end210is shown inserted into the gasket216, this is not essential. The distal end210may simply rest against an outer surface of the gasket216, or be spaced from the gasket216. Furthermore, while the distal end210of the second finger and end of the second portion212bare shown inserted into the gasket parallel to each other and in a substantially vertical direction, it would be understood this was also not essential. Where the gasket216is spaced from the second finger, application of the external force will first slide the gasket216towards the second finger before applying a force to the second finger. While the external force is described as being applied to the gasket216, it would be understood that it was not essential for the force to be applied directly to the gasket216. Intermediate materials or structures may be present between the source of the external force and the gasket216. These intermediate materials or structures may transfer some or all of the force from the source of the external force and the gasket216. Similarly, while the gasket216is shown contacting the second finger, it would be apparent it was not essential for this contact to be directly between the gasket216and the second finger. One or more intermediate materials or structures may be used to transfer some or all of the force from the gasket216to the second finger. Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of them mean “including but not limited to”, and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise. Features, integers, characteristics, or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed. | 23,475 |
11859439 | DESCRIPTION OF THE INVENTION As used herein, spatial or directional terms, such as “left”, “right”, “inner”, “outer”, “above”, “below”, and the like, relate to the invention as it is shown in the drawing figures. However, it is to be understood that the invention can assume various alternative orientations and, accordingly, such terms are not to be considered as limiting. The drawings are not necessarily to scale. Further, as used herein, all numbers expressing dimensions, physical characteristics, processing parameters, quantities of ingredients, reaction conditions, and the like, used in the specification and claims are to be understood as being modified in all instances by the term “about”. Accordingly, unless indicated to the contrary, the numerical values set forth in the following specification and claims may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical value should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Moreover, all ranges disclosed herein are to be understood to encompass the beginning and ending range values and any and all subranges subsumed therein. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more and ending with a maximum value of 10 or less, e.g., 1 to 3.3, 4.7 to 7.5, 5.5 to 10, and the like. “A” or “an” refers to one or more. The articles described herein typically, but not exclusively, find use in architecture. The articles may be discussed with reference to their use in an insulating glass unit (IGU). In an IGU, a spacer described herein may be used to space apart two panels, such as panels used in architectural transparencies. As used herein, the term “architectural transparency” refers to any transparency located on a building, such as, but not limited to, windows and sky lights. However, it is to be understood that the articles described herein are not limited to use with such architectural transparencies but may be practiced with transparencies in any desired field, such as, but not limited to, laminated or non-laminated residential and/or commercial windows, insulating glass units, and/or transparencies for land, air, space, above water, and underwater vehicles. In one aspect or embodiment, the coated articles as described herein are transparencies for use in a vehicle, such as a window or a sunroof. Therefore, it is to be understood that the specifically disclosed exemplary aspects or embodiments are presented simply to explain the general concepts of the invention, and that the invention is not limited to these specific exemplary embodiments. Additionally, while a typical “transparency” can have sufficient visible light transmission such that materials can be viewed through the transparency, the “transparency” need not be transparent to visible light but may be translucent or opaque. That is, by “transparent” is meant having visible light transmission of greater than 0% up to 100%. A non-limiting transparency10is illustrated inFIG.1A. The transparency10may have any desired visible light, infrared radiation, or ultraviolet radiation transmission, transmittance, absorption, and/or reflection profile. The transparency10ofFIG.1Ais in the form of a conventional insulating glass unit and includes a first panel12or ply with a first major surface14(No. 1 surface) and an opposed second major surface16(No. 2 surface). In common usage, when installed into a building, the first major surface14faces the building exterior, e.g., is an outer major surface, and the second major surface16faces the interior of the building. The transparency10also includes a second panel18or ply having an inner (first) major surface20(No. 3 surface) and an outer (second) major surface22(No. 4 surface) and spaced from the first ply12. This numbering of the panel or ply surfaces is in keeping with conventional practice in the fenestration art. In the context of the articles provided herein, the first and second panels12,18are connected using a spacer frame24(“spacer”) as described herein. A gap or chamber26is formed between the two panels12,18. The chamber26may be filled with a selected atmosphere, such as air, or a non-reactive gas such as argon or krypton gas. A solar control coating30(or any of the other coatings described below) may be formed over at least a portion of one of the plies12,18, such as, but not limited to, over at least a portion of the No. 2 surface16or at least a portion of the No. 3 surface20. Although, the coating could also be on the No. 1 surface or the No. 4 surface, if desired. Panels12,18may be the same or different. Non-limiting examples of insulating glass units are found, for example, in U.S. Pat. Nos. 4,193,236; 4,464,874; 5,088,258; and 5,106,663. FIG.1Bdepicts transparency10′, which is a variation of the transparency10depicted inFIG.1A. The transparency10′ ofFIG.1Bis in the form of a conventional insulating glass unit and includes a first panel12′ or ply with a first major surface14′ (No. 1 surface) and an opposed second major surface16′ (No. 2 surface). In common usage, when installed into a building, the first major surface14′ faces the building exterior, e.g., is an outer major surface, and the second major surface16′ faces the interior of the building. The transparency10′ also includes a second panel18′ or ply having an inner (first) major surface20′ (No. 3 surface) and an outer (second) major surface22′ (No. 4 surface) and spaced from the first ply12′. A third panel26′ is disposed between the first panel12′ and the second panel18′. The first and third panels12′,26′ are connected using a spacer frame24′ (“spacer”) as described herein. The second and third panels18′,26′ are connected using a spacer frame24″ (“spacer”) as described herein. Gaps or chambers26″ are formed between the panels12′,26′ and between panels18′,26′, respectively. The chambers26″ may be filled with a selected atmosphere, such as air, or a non-reactive gas such as argon or krypton gas. Panels12′,18′ and26′ may be the same or different. As indicated above, in the broad practice of the invention, the panels12,18,12′,18′,26′ of the transparency10,10′ can be of the same or different materials and may have the same or different dimensions. The panels12,18,12′,18′,26′ may include any desired material having any desired characteristics. For example, one or more of the panels12,18,12′,18′,26′ may be transparent or translucent to visible light. By “transparent” is meant having visible light transmission of greater than 0% up to 100%. Alternatively, one or more of the panels12,18,12′,18′,26′, may be translucent. By “translucent” is meant allowing electromagnetic energy (e.g., visible light) to pass through but diffusing that energy such that objects on the side opposite the viewer are not clearly visible. Examples of suitable materials for the panels include, but are not limited to, plastic substrates (such as acrylic polymers, such as polyacrylates; polyalkylmethacrylates, such as polymethylmethacrylates, polyethylmethacrylates, polypropylmethacrylates, and the like; polyurethanes; polycarbonates; polyalkylterephthalates, such as polyethyleneterephthalate (PET), polypropyleneterephthalates, polybutyleneterephthalates, and the like; polysiloxane-containing polymers; or copolymers of any monomers for preparing these, or any mixtures thereof); ceramic substrates; glass substrates; or mixtures or combinations of any of the above. For example, one or more of the panels12,18,12′,18′,26′ may include conventional soda-lime-silicate glass, borosilicate glass, or leaded glass. The glass may be clear glass. By “clear glass” is meant non-tinted or non-colored glass. Alternatively, the glass may be tinted or otherwise colored glass. The glass may be annealed or heat-treated glass. As used herein, the term “heat treated” means tempered or at least partially tempered. The glass may be of any type, such as conventional float glass, and may be of any composition having any optical properties, e.g., any value of visible transmission, ultraviolet transmission, infrared transmission, and/or total solar energy transmission. By “float glass” is meant glass formed by a conventional float process in which molten glass is deposited onto a molten metal bath and controllably cooled to form a float glass ribbon. Examples of float glass processes are disclosed in U.S. Pat. Nos. 4,466,562 and 4,671,155. The panels12,18,12′,18′,26′ may each comprise, for example, clear float glass or may be tinted or colored glass or one panel12,18,12′,18′,26′ may be clear glass and the other panel(s)12,18,12′,18′,26′, colored glass. Although not limiting, examples of glass suitable for the panels12,18,12′,18′,26′ are described in U.S. Pat. Nos. 4,746,347; 4,792,536; 5,030,593; 5,030,594; 5,240,886; 5,385,872; and 5,393,593. The panels12,18,12′,18′,26′ may be of any desired dimensions, e.g., length, width, shape, or thickness. In one exemplary automotive transparency, the first and second plies may each be 1 mm to 10 mm thick, such as 1 mm to 8 mm thick, such as 2 mm to 8 mm, such as 3 mm to 7 mm, such as 5 mm to 7 mm, such as 6 mm thick. Non-limiting examples of glass that may be used for the panels include clear glass, Starphire®, Solargreen®, Solextra®, GL-20®, GL-35™, Solarbronze®, Solargray® glass, Pacifica® glass, SolarBlue® glass, and Optiblue® glass. The solar control coating30of the invention is deposited over at least a portion of at least one major surface of one of the panels12,18,12′,18′,26′. In the example according toFIG.1A, the coating30is formed over at least a portion of the inner surface16of the outboard glass ply12; additionally or alternatively, it is to be understood that in non-limiting examples consistent with the present disclosure a coating may be formed over at least a portion of the inner surface20of the inboard glass panel18. As used herein, the term “solar control coating” refers to a coating comprised of one or more layers or films that affect the solar properties of the coated article, such as, but not limited to, the amount of solar radiation, for example, visible, infrared, or ultraviolet radiation, reflected from, absorbed by, or passing through the coated article; shading coefficient; emissivity, etc. The solar control coating30may block, absorb, or filter selected portions of the solar spectrum, such as, but not limited to, the IR, UV, and/or visible spectrums. Coatings may be deposited by any useful method, such as, but not limited to, conventional chemical vapor deposition (CVD) and/or physical vapor deposition (PVD) methods. Examples of CVD processes include spray pyrolysis. Examples of PVD processes include electron beam evaporation and vacuum sputtering (such as magnetron sputter vapor deposition (MSVD)). Other coating methods could also be used, such as, but not limited to, sol-gel deposition. In one non-limiting embodiment, the coating30is deposited by MSVD. Examples of MSVD coating devices and methods will be well understood by one of ordinary skill in the art and are described, for example and without limitation, in U.S. Pat. Nos. 4,379,040; 4,861,669; 4,898,789; 4,898,790; 4,900,633; 4,920,006; 4,938,857; 5,328,768; and 5,492,750. FIG.2is an elevation view (left) and a cross-sectional view (right) of an insulating glazing unit (IGU)100, with a central area102and a peripheral area104, defined by the dotted line. In the cross-sectional view, panels112,118and compartment124are depicted. Peripheral area may comprise an area extending any suitable distance, such as, without limitation from 1″ to 24″, including any increment therebetween, such as 1″, 2″, 3″, 4″, 5″, 6″, 7″, 8″, 9″, 10″, 11″, or 12″, from an edge of the panel, and may depend on the dimensions of the IGU. The peripheral area may be peripheral to, that is, in a direction toward the edges of the IGU, the sight line of the IGU100. According to one aspect or embodiment, a spacer is provided for use in an IGU, such as described in connection withFIGS.1A,1B, and2.FIGS.3A,3B,4A, and4Beach depict cross-sections of exemplary spacers incorporated into an IGU.FIG.3Adepicts a peripheral portion204of an IGU200, and depicts a first panel212, a second panel218, and a spacer224, defining a chamber226, e.g., as described in connection withFIGS.1A,1B and2(chambers26,26′,26″,126).FIGS.3A,3B,4A, and4B, for simplicity, depict only a peripheral portion of one side of the IGU. The spacer is attached to and extends continuously around the peripheral portion204of IGU200, for example as depicted inFIG.2. Adhesive230is used to affix the spacer224between panels212,218. The spacer comprises lateral walls232,232′, each having a lip234,234′ extending inwardly towards the opposite lip234,234′. The lips234,234′ define a gap therebetween. Depicted are three longitudinally-extending ridges236,236′, and236″ that extend along the length of the spacer224. The ridges236,236′,236″ each comprise two walls238, connected by a peak portion240(labeled inFIG.3Aonly for first lateral ridge236). Lateral ridges236and236″ are attached to adjacent lateral walls,232and232′, and ridges236,236′,236″ are attached to each other by a valley portion242, which define, on the chamber or interior side of the spacer224lateral valleys244and central valleys244′. A desiccant matrix246is deposited in the central valleys244′. FIG.3Bdepicts a peripheral portion of an IGU300, substantially as described with regard toFIG.3A. The spacer324is affixed to the panels212,218using two different adhesives330and331. Adhesive330may be hot melt butyl, polyisobutylene (PIB), or hot applied curable material and adhesive331may be silicone, polysulfide, polyurethane, hot applied butyl, or a hot-applied curable material. The spacer324includes two longitudinally-extending ridges336,336′ defining a central valley344into which a desiccant matrix346deposited. A gap G between lips334and334′ is depicted, as is the height Hs of the spacer, and the height HRof the ridges336,336′, which measurements are applicable to the various examples of spacers described herein. The height Hs of the spacer and the height HRof the ridges are measured in the same direction and may be measured perpendicular to the longitudinal axis of the spacer, and parallel to the panels or the lateral walls of the spacer, representing the shortest distance from the most peripheral point, e.g., the bottom of the valleys, and the most internal point, e.g., the lips or the gap between the lips, of the spacer. FIG.3Cdepicts a further variation of the spacer224ofFIG.3A. As shown inFIG.3C, adhesive231is distributed between the panels212and218below the valley portions242. The adhesive231is also distributed into the space233formed between the two walls238and connecting peak portions240of the ridges236,236′,236″. It is appreciated that the adhesive231can comprise any of the materials previously described with respect to adhesive331, such as for example silicone, polysulfide, polyurethane, hot applied butyl, or a hot-applied curable material. FIG.3Ddepicts yet another variation of the spacer224ofFIGS.3A and3C. As shown inFIG.3D, a barrier member241is placed across the valley portions242and extends across all the valley portions242to block access to the space233formed between the two walls238and connecting peak portions240of the ridges236,236′,236″. As further shown inFIG.3D, adhesive231is distributed between the panels212and218below the valley portions242. Because the barrier member241is placed across the valley portions242, adhesive231does not enter the space233formed between the two walls238and connecting peak portions240of the ridges236,236′,236″. Rather, the space233formed between the two walls238and connecting peak portions240of the ridges236,236′,236″ is filled with air. The barrier member241can comprise any material that can be attached to the valley portions242and which prevents adhesive231from entering the space233, such as a for example a tape that can be adhered to the valley portions242and prevents adhesive231from entering the space233. It is appreciated that less adhesive231is used to cover the area under the valley portions242when the barrier member241is used. FIGS.4A and4Bdepict IGUs400,400′ that include variations of the spacer224and324ofFIGS.3A and3B, respectively. All elements of IGUs400,400′ are essentially as depicted inFIGS.3A and3B. Spacers424,424′ comprise lateral walls432,432′ and lateral valleys442,442′, with lateral folds433,433′ connecting the lateral walls432,432′ and lateral valleys442,442′. The lateral folds433,433′ extend at an angle θ from a plane P of the lateral walls432,432′, as shown inFIG.4B, which may be any angle θ between 0° and 90°, such as 5°, 10°, 22.5°, 30°, 45°, or 60° and may be the same or different for lateral folds433and433′. In a variation of the ridges depicted inFIGS.3A and3B, peak portions440and central valley portions443are squared, or comprise planar portions perpendicular to the lateral walls432. The squaring of the valley portions443and peak portions440impart different mechanical strength to the spacer424and therefore to the IGU400, allowing for tailoring of the mechanical strength of the IGU, for example compressibility. Optionally, lateral valley portions442may be squared as with central valley portions443. Any IGU described herein may include, independently, more or less rounded, or more or less squared, peak portions and/or valley portions as design variants. A spacer, as described herein, for example inFIGS.3A,3B,3C, and3D, may be formed from a single sheet of metal. The metal from which the spacer is formed may be stainless steel or tin-plated steel. A spacer frame, that surrounds the internal cavity of an IGU as described herein, may be formed from a single contiguous sheet of metal, or by joining two or more separate spacer frame portions formed from two or more sheets of metal. For ease of manufacture, it may be preferred that the spacer frame is formed from a single sheet of metal, for example as described below. In the context of the IGUs and spacers described herein, “parallel” means that a portion of a stated element, such as a wall of the spacer is parallel to the plane of the referenced element, such as a panel, within practical manufacturing tolerances, e.g., within ±1° of parallel. “Substantially parallel,” meaning that a portion of a stated element, such as a wall of the spacer is parallel to, or within ±1°, ±2°, ±3°, ±4°, or ±5° of the plane of the referenced planar element, such as a panel. Likewise, “perpendicular” means that a portion of a stated element, such as a wall of the spacer is perpendicular to the plane of the referenced planar element, such as a panel, within practical manufacturing tolerances, e.g., within ±1° of perpendicular (90°). “Substantially perpendicular” refers to a portion of a stated element, such as a wall of the spacer is perpendicular to, or within ±1°, ±2°, ±3°, ±4°, or ±5° of a plane perpendicular to a plane of the referenced planar element, such as a panel. By “free of desiccant”, e.g., in the context of valleys formed by ridges on the internal side of the spacer, it is meant that the valleys, e.g., the lateral valleys, do not contain desiccant, or only contain small amounts of desiccant, for example as compared to the central valleys, for example as a result in inaccuracy of deposition or movement of the desiccant matrix during manufacture of an insulated glazing unit, within manufacturing tolerances. The spacers may be prepared by any useful method. Because the spacers may be prepare from a single coil of metal stock, roll-forming may be preferred for preparing the spacer as depicted schematically inFIG.5. In roll-forming, a metal strip passes through sets of rolls mounted on consecutive stands, each set performing only an incremental part of a desired bend, until the desired cross-section (profile) is obtained. InFIG.5, coiled metal stock is uncoiled and is fed sequentially through roll stations (not depicted) to produce stock spacer. Referring toFIG.5, left, the forming process proceeds from a sheet (bottom, showing the first incremental folding to form the lips) to the fully-formed spacer profile (top).FIG.5, right, shows the sheet overlayed at various folding stages, to depict the progress of the folding and the increments at each step (bottom) for one example of a spacer configuration. One spacer profile is depicted inFIG.5, though any spacer profile, such as those depicted inFIG.3A,3B,4A, or4B, may be prepared in this manner. The spacer is cut to length after roll-forming, and the lineal key tab is swaged for end-joining the spacer after folding. Corner clearances, end-swaging, and muntin bar locators may be cut into the metal stock prior to roll-forming, or after roll-forming the spacer. Adhesive, such as a hot-melt butyl or hot-applied curable material and desiccant matrix, e.g. a polyisobutylene (PIB) adhesive, for example as are broadly-known in the art, are applied to the spacer after formation and cutting. Desiccant matrix is deposited in central valleys of the spacer, and not to lateral valleys of the spacer, before, during, or after application of the adhesive to the lateral walls of the spacer, e.g., as depicted inFIGS.3A,3B,4A, and4B. Desiccant matrix is not applied at the corners, that is, at or adjacent to corner clearances cut in the spacer. Continuing in the production line, after roll forming and deposition of adhesive and desiccant, the spacer may folded into shape using interior and exterior forming dies, and the swaged ends may be joined by any useful method. FIG.6is a flow diagram providing an overview of a method500of preparing an IGU as described herein that can be performed as a continuous process that is substantially automated (see Examples 1 and 2, below). As described in connection withFIG.5, coiled stock is roll-formed and cut502into individual spacer units. Desiccant and adhesive is then applied504. Using internal and external dies, the spacer is folded506into a desired shape, such as a rectangular frame. The Frame is further processed508by adding the panels and air or an inert gas into the interior compartment. Muntins also may be added at this step508. Steps502,504, and506may be fully automated. Step508may be fully automated, or workers may assist in the assembly of the IGU. An example of a spacer624is shown inFIG.7.FIG.7provides two views of a spacer essentially as depicted inFIG.3B, including corner clearances650and swaged ends652, which assist in formation of a spacer frame from the spacer.FIG.8depicts the spacer624ofFIG.7, partially folded (left) with the swaged ends not joined, and fully folded (right), with the swaged ends locked in place. The swaged ends may be locked in place by any useful method, either mechanically, e.g. using tabs, welded, or by any useful method. The spacer, such as a spacer as depicted inFIGS.7and8, may be bent as shown inFIG.8by mandrel bending using internal and external dies. FIGS.9A and9Bdepict schematically an internal die700, withFIG.9Bbeing rotated 90° as shown inFIG.9Aat A.FIG.9Bis a cross-section of the device the internal die700at B. The internal die700includes protuberances702that match the internal shape of a spacer, such as spacer324ofFIG.3B, depicting upper U and lower L limits or boundaries of protuberances702. The internal die700is attached to any suitable mechanical actuator via rod704. As would be recognized, the actuation of the internal die700can be accomplished by a significant variety of mechanical mechanisms, a rod and a suitable actuator for the rod, such as a cam or lever (not shown), being merely exemplary. FIGS.10A and10Bdepict external die710, withFIG.10Bbeing rotated 90° as shown inFIG.10Aat B.FIG.10Bis a cross section of10A at A. External die710includes protuberances712and peripheral guides714and may be attached to any suitable mechanical actuator via rod716. As would be recognized by one of ordinary skill, the actuation of the external die710can be accomplished by a significant variety of mechanical mechanisms, a rod and a suitable actuator for the rod, such as a cam or lever (not shown), being merely exemplary. Internal die700fits or nests within external die710, with a suitable gap to accommodate the thickness of a spacer placed between the dies700,710. Tip720of the internal die700may be rounded.FIG.10Adepicts upper limits or boundaries U and lower limits or boundaries L of the protuberances712. FIG.11depicts dies700and710in use. Die700is placed internal to a spacer724at a location of a corner clearance750, and external die710is aligned external to the spacer724. As described herein, the area of the corner clearance750is free of desiccant matrix and adhesive, to facilitate the bending process. Protuberances of the internal and external dies700,710are aligned with ridges of the spacer724. Protuberances of the dies700,710and ridges of the spacer724are not shown inFIG.11for clarity. The internal and external dies700,710are moved together as shown by the arrows (top), and bend the spacer724to a final, bent configuration (bottom), with edges of the corner clearance751either meeting, or alternatively, overlapping or not meeting, depending on the shape of the corner clearance750. The use of the two dies700,710in mandrel bending results in a bent corner with metal of the spacer being bent and/or stretched in the mandrel bending process. The spacers described herein exhibit exceptional insulation, e.g., Res-values, when incorporated into an IGU.FIG.12depicts a metal sheet800and a spacer formed from the metal sheet824, essentially as depicted inFIG.3A. The metal sheet has a linear width Wshand is folded longitudinally to form a spacer having a width Wsp. In certain aspects, the spacer is folded in a shape in which Wsp/Wsh×100% is 36% or less, 35% or less, e.g., 25% or less, 20% or less, or 15% or less, e.g., ranging from 15% to 35%, or from 21% to 30%. This high degree of folding results in superior resistance to heat flow, or insulative capacity when incorporated into an IGU. In certain aspects, the thermal resistance (Res-value [(in-hr-° F.)/BTU]) of the spacer when incorporated into an IGU is at least 175, at least 190, at least 175, at least 190, at least 195, at least 200, at least 205, at least 210, or at least 215. U.S. Pat. Nos. 5,655,282, 5,675,944 and 6,115,989, among many others, describe IGUs, methods of making IGUs, and various applicable standards for assessing the insulating capacity of IGUs. IGUs may be used to reduce heat transfer between the outside and inside of a home or other structures. A measure of insulating value generally used is the “U-value”. The U-value is the measure of heat in British Thermal Unit (BTU) passing through the unit per hour (hr)-square foot (ft2)-degree Fahrenheit (° F.) (Formula 1): BTU(hr)(ft2)(°F.).(1) The lower the U-value the better the thermal insulating value of the unit, e.g., higher resistance to heat flow resulting in less heat conducted through the unit. Another measure of insulating value is the “R-value” which is the inverse of the U-value. Still another measure is the resistance to heat flow (Res-value) which is stated in hr-° F. per BTU per inch of perimeter of the unit (Formula 2): (hr)(°F.)BTU/in.(2) Modeling software, such as ANSYS finite element code (i.e. ANSYS; Finite Element Program {FEA}, Release 14, SAS IC. Inc. 2012), may be used to determine the Res-value (see, e.g., European Patent Application Publication Number 0 475 213 A1 and U.S. Pat. Nos. 5,531,047 and 5,655,282). The result of the ANSYS calculation is dependent on the geometry of the cross section of the edge assembly and the thermal conductivity of the constituents thereof. The geometry of any such cross section may be measured by studying the unit edge assembly. In some aspects, the edge resistance of the edge assembly (hr·° F.·in/BTU) is defined by the inverse of the flow of the (BTU/hr·° F.·in.), calculated by ANSYS, that occurs from the interface of the glass and adhesive layer at the inside side of the unit to the interface of the glass and adhesive layer of the outside of the unit per unit increment of temperature (1° F.), per unit length of edge assembly perimeter (inch). The glass/adhesive interfaces are assumed to be isothermal to simplify the model. As such, in certain examples, a spacer is provided, and an IGU is provided, where the spacer is formed from a single, folded metal sheet, such as a stainless steel or tin-plated steel sheet, where Wsp/Wsh×100% is 36% or less, at most 35%, e.g., 25% or less, 20% or less, or 15% or less, e.g., ranging from 15% to 35%, or from 21% to 30%, and having a Res-value of at least 175, at least 190, at least 175, at least 190, at least 195, at least 200, at least 205, at least 210, or at least 215 when the spacer is incorporated into an IGU. Comparative Example 1 Spacers are automatically formed as follows: Flat metal coil is fed from an uncoiler to a feeder press where corners, muntin bar locators, corner tabs, and gas fill holes are punched. After punching, the flat coil stock advances to a roll former where it is bent into the proprietary U-shape. At the roll former exit, individual IGU spacers are automatically cut to length, corner tabs are swaged, and advanced via a conveyor belt to the adhesive and desiccant matrix extruder. Adhesive (usually a hot melt butyl or hot applied curable material) and desiccant matrix is applied by the extruder in a linear fashion to the un-bent spacer as it advances on a conveyor belt. A worker folds the spacer (with adhesive and desiccant matrix applied), inserts the preformed tab to form a rectangular shape and hangs it on the overhead conveyor. Two glass lites are washed in a horizontal washer and advance to the spacer topping station. A worker removes a spacer from the overhead conveyor and with assistance from a second worker places the spacer on the first glass lite. The two workers then place the second glass lite on top of the spacer. Low strength adhesion is established via the initial adhesive “tack” and the IGU advances to the heated oven/roll press. Final overall thickness, adhesive bond line width, and adhesion is achieved by high heat and pressure through the continuously moving oven/roll press. Workers inspect and offload the IGUs and place them on transport racks for cooling. After the IGUs reach room temperature, they are argon filled via lances in batches of 5 at a time by a worker. After argon filling is complete, screws are inserted in the fill holes and a hot melt butyl patch is applied by a worker. The IGUs are finished and ready for installation in the window sash. Comparative Example 2 Metal spacer material is roll formed and cut into standard lengths. This is often done at a dedicated plant outside of the IGU manufacturing facility. A section of formed spacer metal is cut to length by a worker. The spacer metal is bent to the desired rectangular shape (corners formed) by a worker. A worker drills holes in the spacer to enable desiccant bead filling. Desiccant beads “injected” into spacer by the same worker. Drilled holes are manually patched closed with foil tape or butyl adhesive by the same worker. Primary adhesive (polyisobutylene or PIB) is applied by a worker using a “cartwheel” motion with a PIB extruder. Spacer is placed on overhead conveyor. The first lite of glass exits the vertical glass washer and advances to the spacer topping station. Spacer is removed from overhead conveyor and positioned by a worker on the first glass lite. The glass and spacer advance to the argon filling press. The second glass exits the washer and advances to the argon filling press. The two glass lites are flooded with argon and pressed together. Low strength adhesion is achieved via the PIB, forming the IGU. The IGU advances to the secondary adhesive robot. Secondary adhesive (usually silicone or polysulfide—sometimes polyurethane, hot applied butyl, or a hot applied curable material) is applied to the back of the spacer. The finished IGU exits the robot sealer and is inspected then removed from the manufacturing line. The IGUs are finished and ready for installation in the window sash. Comparative Example 3 Metal spacer material is roll formed and cut into standard lengths (e.g., about 21′ long). This is often done at a dedicated plant outside of the IGU manufacturing facility. A section of formed spacer metal is cut to length by a worker. A lineal key is inserted in one end of the spacer by a worker. Desiccant beads are filled through the open end. The spacer metal is bent to the desired rectangular shape (corners formed). Primary adhesive (PIB) is applied by a worker using a “cartwheel” motion with a PIB extruder. Spacer is placed on overhead conveyor. The first lite of glass exits the vertical glass washer and advances to the spacer topping station. Spacer is removed from overhead conveyor and positioned by a worker on the first glass lite. The glass and spacer advance to the argon filling press. The second glass exits the washer and advances to the argon filling press. The two glass lites are flooded with argon and pressed together. Low strength adhesion is achieved via the PIB, forming the IGU. The IGU advances to the secondary adhesive robot. One part silicone secondary adhesive is applied to the back of the spacer. The finished IGU exits the robot sealer and is inspected then removed from the manufacturing line. The IGUs are finished and ready for installation in the window sash. Example 1—Single Seal Insulating Glass Spacers are automatically formed by the machine in the following order: Flat metal coil is fed from an uncoiler to a feeder press where muntin bar locators and corner clearances are punched. After punching, the flat coil stock advances to a roll former where it is bent into the proprietary shape. At the roll former exit, individual IGU spacers are automatically cut to length, the lineal key tab is swaged, and advanced via a conveyor belt to the adhesive and desiccant matrix extruder. Adhesive (usually a hot melt butyl or hot applied curable material) and desiccant matrix is applied by the extruder in a linear fashion to the un-bent spacer as it advances on a conveyor belt. Desiccant matrix is not applied to the corner areas. The spacer bender bends the spacer by use of interior and exterior forming dies, referred to herein as mandrel bending. The same machine inserts the swaged end of the spacer into the trailing end of the spacer. Spacer joining techniques may include: spot welding, positive locking/mating stamped sections, adhesive adhesives, and foil tapes. The finished spacer is collected by an automated overhead conveyor. Two glass lites are washed in a horizontal washer and advance to the spacer topping station. A worker removes a spacer from the overhead conveyor and with assistance from a second worker places the spacer on the first glass lite. The two workers then place the second glass lite on top of the spacer. Low strength adhesion is established via the initial adhesive “tack” and the IGU advances to the heated oven/roll press. Final overall thickness, adhesive bond line width, and adhesion is achieved by high heat and pressure through the continuously moving oven/roll press. Workers inspect and offload the IGUs and place them on transport racks for cooling. After the IGUs reach room temperature, they are argon filled via lances in batches of 5 at a time by a worker. After argon filling is complete, screws are inserted in the fill holes and a hot melt butyl patch is applied by a worker. The IGUs are finished and ready for installation in the window sash. Example 2—Dual Seal Insulating Glass Spacers are automatically formed by the machine in the following order: Flat metal coil is fed from an uncoiler to a feeder press where muntin bar locators and corner clearances are punched. After punching, the flat coil stock advances to a roll former where it is bent into the proprietary shape. At the roll former exit, individual IGU spacers are automatically cut to length, the lineal key tab is swaged, and advanced via a conveyor belt to the primary adhesive and desiccant matrix extruder. Primary adhesive (e.g., polyisobutylene, PIB) and desiccant matrix is applied by the extruder in a linear fashion to the un-bent spacer as it advances on a conveyor belt. Desiccant matrix is not applied to the corner areas. The spacer bender bends the spacer by use of interior and exterior forming dies. The action is described as mandrel bending. The same machine inserts the swaged end of the spacer into the trailing end of the spacer. Spacer joining techniques may include: spot welding, positive locking/mating stamped sections, adhesive adhesives, and/or foil tapes. The finished spacer is collected by an automated overhead conveyor. The first lite of glass exits the vertical glass washer and advances to the spacer topping station Spacer is removed from overhead conveyor and positioned by a worker on the first glass lite. The glass and spacer advance to the argon filling press. The second glass exits the washer and advances to the argon filling press. The two glass lites are flooded with argon and pressed together. Low strength adhesion is achieved via the PIB, forming the IGU. The IGU advances to the secondary adhesive robot. Secondary adhesive (usually silicone or polysulfide—sometimes polyurethane, hot applied butyl, or a hot applied curable material) is applied to the back of the spacer. The finished IGU exits the robot sealer and is inspected, then removed from the manufacturing line. The IGUs are finished and ready for installation in the window sash. Example 3—Dual Seal Insulating Glass with Barrier Member Spacers are automatically formed by the machine in the following order: Flat metal coil is fed from an uncoiler to a feeder press where muntin bar locators and corner clearances are punched. After punching, the flat coil stock advances to a roll former where it is bent into the proprietary shape. At the roll former exit, individual IGU spacers are automatically cut to length, the lineal key tab is swaged, and advanced to a barrier member applicator (example of such is a pressure sensitive tape), then advances via a conveyor belt to the primary adhesive and desiccant matrix extruder. Primary adhesive (e.g., polyisobutylene, PIB) and desiccant matrix is applied by the extruder in a linear fashion to the un-bent spacer as it advances on a conveyor belt. Desiccant matrix is not applied to the corner areas. The spacer bender bends the spacer by use of interior and exterior forming dies. The action is described as mandrel bending. The same machine inserts the swaged end of the spacer into the trailing end of the spacer. Spacer joining techniques may include: spot welding, positive locking/mating stamped sections, adhesive adhesives, and/or foil tapes. The finished spacer is collected by an automated overhead conveyor. The first lite of glass exits the vertical glass washer and advances to the spacer topping station Spacer is removed from overhead conveyor and positioned by a worker on the first glass lite. The glass and spacer advance to the argon filling press. The second glass exits the washer and advances to the argon filling press. The two glass lites are flooded with argon and pressed together. Low strength adhesion is achieved via the PIB, forming the IGU. The IGU advances to the secondary adhesive robot. Secondary adhesive (usually silicone or polysulfide—sometimes polyurethane, hot applied butyl, or a hot applied curable material) is applied to the back of the spacer. The finished IGU exits the robot sealer and is inspected, then removed from the manufacturing line. The IGUs are finished and ready for installation in the window sash. Example 4—U-Factor Determination Simulation results for fourteen spacers in a generic vinyl casement frame were obtained. One IGU with the same glass in each was built for a generic vinyl casement frame and evaluated with14different spacers. The data collected included U-factor (Center-of-Glass and Total Product), and also temperature of the glass in the sill sections. The glass option imported into each window was a 3 mm pane of Vitro Solarban®60 coated glass—½″ gap of 90% Argon/10% Air—3 mm pane of clear glass. The ½″ gap was modified if the spacer plus adhesive was not manufactured at exactly that dimension. All software used was by Lawrence Berkley National Laboratory and is considered the industry standard: Window7 software used is version 7.4.14.0; Therm7 software used is version 7.4.4.0; International Glazing Data Base used is version 60. Table 1 includes Center-of-Glass U-factor, Total Window Product U-factor, and sill glass interior surface temperature at the glass sightline for experimental spacer1, essentially shown inFIG.3A, and various comparative examples. Experimental SPACER1: Spacer Height: 0.300″Ridge Spacing: 0.122″Metal thickness: 0.0077″Ridge height: 0.190″Overall width of spacer: 0.450″Adhesive thickness: 0.0235″Adhesive height: 0.273″Metal conductivity, emissivity: 7.875 BTU/hr-ft-F, 0.9Adhesive conductivity, emissivity: 0.139 BTU/hr-ft-F, 0.9Desiccant matrix conductivity, emissivity: 0.168 BTU/hr-ft-F, 0.9 TABLE 1GlassArgonU-U-TemperatureSpace,factorfactorat SillSpacer OptioninchesCOGTotal(° F.)Vitro Intercept Ultra0.5000.24710.261737.3Vitro Intercept Thinplate0.5000.24710.269335.0Vitro Intercept Tinplate0.5000.24710.270434.7Super Spacer Standard with0.5000.24710.259337.93/16″ Secondary SealSuper Spacer Premium Plus0.5000.24710.259138.0Enhanced with 3/16″Secondary SealDuralite0.5000.24710.253939.6Duraseal0.5000.24710.265436.4Tremco EnerEDGE with0.5000.24710.257238.63/16″ Secondary SealKommerling Kodispace0.5000.24710.258138.44SG TPSCardinal XL Edge0.4900.24690.263236.8Cardinal Endur0.4900.24690.260637.5Swiss Spacer Ultimate0.5170.24830.257838.8with 3/16″ SecondarySealAllmetal Aluminum with0.5000.24710.284728.83/16″ Secondary SealIntercept QUANTUM0.5000.24710.254738.6SingleSealIntercept QUANTUM0.5000.24710.253838.7DualSealIntercept QUANTUM0.5000.24710.262436.5Thinplate SingleSealIntercept QUANTUM0.5000.24710.261436.8Thinplate DualSeal Example 4—Res-Value Determination Res values were modeled for a number of variations of the spacer described herein and were compared to values obtained from commercial comparative examples, as well as other spacer variations. Res-values, or edge resistance values ((in-hr-° F.)/BTU) were determined essentially as described in European Patent Application Publication Number 0 475 213 A1 and U.S. Pat. Nos. 5,531,047 and 5,655,282, among others. In short, the edge resistance of the edge assembly (hr·° F.·in/BTU) was defined by the inverse of the flow of the (BTU/hr·° F.·in.), calculated by ANSYS, that occurs from the interface of the glass and adhesive layer at the inside side of the unit to the interface of the glass and adhesive layer of the outside of the unit per unit increment of temperature (1° F.), per unit length of edge assembly perimeter (inch). The glass/adhesive interfaces are assumed to be isothermal to simplify the model. FIG.3Adepicts spacer224having the profile of experimental spacer1.FIG.13provides a schematic diagrams of experimental spacer2.FIG.3Bdepicts spacer324having the profile of experimental spacer3(see alsoFIG.16).FIG.14provides a schematic diagrams of experimental spacer4.FIG.15depicts the comparative INTERCEPT ULTRA Stainless Steel spacer. Res-values for those spacers are depicted in Table 2. TABLE 2Res - valueSpacer Technology[(in-hr-° F.)/BTU]Intercept ULTRA Stainless Steel105Experimental Spacer 4127Experimental Spacer 2138Experimental spacer 3187Experimental Spacer 1216 Example 5—Exemplary Spacers FIG.17provides a table providing exemplary spacer dimensions for the spacers described herein. In reference toFIG.12, Wspis the spacer width, Wshrefers to the width of the metal strip or coil used to fabricate the spacer. Single seal refers to use of a single adhesive, and dual seal refers to use of two adhesives, for example as shown inFIGS.3A and3B, respectively. Frame configuration is in reference toFIGS.3A(configuration A) and3B (configuration B). For all examples, the size and shape of the central region, between the lateral walls, is held constant. In another example, for spacers having a width of 15/32″, the width of the metal in the central folded region, excluding lateral walls and lips, is 1.019″ for a single-seal spacer, and 0.897″ for a dual-seal spacer. It will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed in the foregoing description. Accordingly, the particular embodiments described in detail herein are illustrative only and are not limiting to the scope of the invention, which is to be given the full breadth of the appended claims and any and all equivalents thereof. | 45,446 |
11859440 | Embodiments of the invention and their advantages are best understood by referring to the detailed description that follows. It should be appreciated that like reference numerals are used to identify like elements illustrated in one or more of the figures. DETAILED DESCRIPTION In accordance with various embodiments of the present disclosure, multi-panel architectural coverings, such as garage doors, retractable storefronts, windows, entry doors, or the like, benefit from a vacuum insulated frame design. The frame may define at least one opening within which a transparent or translucent window or other inset panel is secured. Each opening may be defined by a pair of rails secured to a pair of stiles at respective interfaces. The interfaces may be sealed in a manner allowing a vacuum to be created inside at least a portion of the frame. The architectural covering may include a plurality of panels, each panel including the frame design described herein. The multiple panels of the architectural covering may be secured together via one or more hinges to allow articulation of the covering as the covering is moved between positions, such as to enable movement of the covering along a track between a vertical (closed) position and a horizontal (open or overhead) position. FIG.1illustrates a front perspective view of a multi-panel covering100for an architectural opening in accordance with an embodiment of the disclosure.FIG.2illustrates a rear view of the multi-panel covering100ofFIG.1in accordance with an embodiment of the disclosure. The covering100may be any type of apparatus configured to cover or otherwise fill an architectural opening104. For example, the architectural opening104may be a framed opening of a structure or building106, such as a garage door opening, a doorway, a window frame, a storefront opening, or the like. The covering100may be configured to at least partially cover or fill the architectural opening104. For example, the covering100may be a garage door configured to fill or fit within a garage door opening, a door configured to fill or fit within a doorway, a window configured to fill or fit within a window frame, or a door or panel configured to fill or fit within a storefront opening. For ease of reference, however,FIGS.1-2illustrate the covering100as a garage door, though other configurations are contemplated. Depending on the application, the covering100may be a sectional or multi-panel door. For instance, the covering100may include a plurality of panels102that together at least partially enclose an opening104in a building or other structure106. In the embodiments illustrated inFIGS.1-2, for example, the covering100includes a first panel110, a second panel112, a third panel114, and a fourth panel116that close, cover, or fit within a garage opening defined by two jambs, a header, and a driveway or garage floor, though other configurations are contemplated. For instance, the covering100may include any number of panels102and may be located in any suitable opening104of a building or other structure106. The plurality of panels102may be configured identical to one another or may be different from one another. For instance, the first panel110, second panel112, third panel114, and fourth panel116, or any combination thereof, may be identical to one another. In some embodiments, the first panel110, second panel112, third panel114, and fourth panel116, or any combination thereof, may be configured different from one another, such as include differing heights, configurations, or the like. With continued reference toFIGS.1-2, each panel102may include many configurations. For example, at least one of the plurality of panels102may include a frame120defining at least one opening122, and an inset panel124secured within the at least one opening122. For example, the frame120may define a plurality of openings122, and a respective inset panel124may be secured within each opening122of the frame120. The inset panel124may include many configurations. For instance, the inset panel124may be an insulated member to provide an insulation characteristic. In some embodiments, the inset panel124may be a transparent, non-transparent, or translucent window, although other configurations are contemplated. The window may include multiple panes of glass, with the spaces between the panes turned into a vacuum or filled with gas with a lower thermal conductivity and heat capacity than “air.” The inset panel124may be a pane of glass, polymer, metal, natural material such as wood, or other material. In some embodiments, the inset panel124may be sealed along its sides to interface with the frame120. In embodiments, the inset panel124may be configured to prevent air from moving from a first side of the inset panel124to a second side of the inset panel124. In some embodiments, the frame120may define an insulation characteristic of the covering100. For instance, the frame120may be sealed to allow for a vacuum to be created inside the frame120, as described in more detail below. In other embodiments, the frame120may be filled with a low conductivity gas (e.g., argon or similar gas) to provide an insulation characteristic, as described below. In some embodiments, the frame120may be formed from materials with low thermal conductivity, such as stainless steel, aluminum, or other material, to decrease the thermal conductivity of the frame120itself. The low thermal conductivity of the frame120may also limit or prevent condensation formation on the frame120, which may be beneficial in cold weather applications. Each opening122of the frame120may be defined by a plurality of first frame members (e.g., a pair of rails130) secured to a plurality of second frame members (e.g., a pair of stiles132) at respective interfaces134. The interfaces134may seal the rails130to the stiles132to allow for a vacuum to be created inside at least a portion of the frame120. For example, the rails130may be welded to the stiles132to create an airtight interface between the rails130and stiles132. Welding the stiles132to the rails130may provide a more ridged frame that will leak less air than a conventional bolted design. However, although welding is mentioned specifically, other suitable connection methods are contemplated that create an airtight interface and allow for a vacuum to be created inside at least a portion of the frame120. For example, soldering, brazing, friction welding, laser welding, press-fitting, or using malleable or compressible materials are contemplated in addition to traditional and non-traditional welding methods that may or may not include welding filler materials to seal the joint. Depending on the application, the rails130and/or stiles132of one opening122may also define the rails130and/or stiles132of an adjacent opening122. For instance, a single stile may define portions of horizontally adjacent openings122and/or vertically adjacent openings122of the frame120. Similarly, a single rail may define portions of horizontally adjacent openings122and/or vertically adjacent openings122of the frame120. In this manner, a single stile may run a vertical length of the frame120and/or a single rail may run a horizontal width of the frame120to define two or more adjacent openings122. In some embodiments, the plurality of panels102may be movably connected to move between positions, such as between a closed position and an open position, between a closed position and an overhead position, or otherwise between a first position and a second position. As shown inFIG.2, the plurality of panels102may be pivotably connected via one or more hinges140. For example, the multi-panel covering100may include one or more hinges140securing the first panel110to the second panel112, one or more hinges140securing the second panel112to the third panel114, and so on. In such embodiments, the first panel110may pivot relative to the second panel112, the second panel112may pivot relative to the third panel114, and so on to allow articulation of the covering100as the covering100is moved between positions, such as to enable movement of the covering100along a track of a garage door between a vertical (closed) position and a horizontal (open or overhead) position, though other configurations are contemplated. Referring toFIG.2, the hinges140may be secured to the panels102in many configurations. For instance, the hinges140may be welded to the panels102, secured to the panels102via mechanical fasteners, formed integrally with one or more portions of the frame120, or the like. In some embodiments, the hinges140may be secured to the panels102in a manner that does not compromise the integrity of a vacuum within the frame120. For instance, in one or more embodiments, the hinges140may be secured to the panels102via a T-slot profile defined in each of the panels102. For instance, at least a portion of the frame120, such as at least a portion of a rail or stile, may have a profile having one or more channels or protrusions used to connect the hinges140to the frame120. In such embodiments, the head of a bolt may be positioned within the channel for attaching the hinges140to the frame120. In some embodiments, the attachment mechanism between the frame120and the hinges140may be similar to the 80/20 system of 80/20 Inc. FIG.3illustrates a front perspective view of a panel300of a multi-panel covering for an architectural opening in accordance with an embodiment of the disclosure.FIG.4illustrates an exploded view of the panel300in accordance with an embodiment of the disclosure. Referring toFIGS.3-4, the panel300may be configured to at least partially cover an architectural opening, such as a garage opening, a storefront opening, or the like. In this manner, the panel300may form part of a multi-panel covering, such as covering ofFIGS.1-2, described above. Accordingly, each of the panels102described above with reference to covering ofFIGS.1-2may be similar to the panel300illustrated in and described with reference toFIGS.3-4. As shown inFIGS.3-4, the panel300may include a frame302defined by a plurality of frame members304, such as a first rail310, a second rail312, and a plurality of stiles314(e.g., a pair of stiles314, more than two stiles314, etc.) connected to and separating the first rail310and the second rail312. As shown, the panel300includes a first stile320, a second stile322, a third stile324, and a fourth stile326. However, other configurations are contemplated, such as a lesser number of stiles314or a greater number of stiles314than illustrated. Accordingly, the configuration illustrated inFIGS.3-4and described below may be modified for different frame configurations. For example, in embodiments with only a pair of stiles314the second stile322and third stile324may be omitted. Similarly, only one of the second stile322and the third stile324may be omitted, one or more additional stiles314may be added between the first and fourth stiles320,326, or the like. The frame302may be similar to the frame120ofFIGS.1-2, described above. Depending on the application, the panel300may include one or more openings defined by the frame members304. For example, the first rail310, second rail312, first stile320, and second stile322may define a first opening330of the panel300. Similarly, the first rail310, second rail312, second stile322, and third stile324may define a second opening332of the panel300, and the first rail310, second rail312, third stile324, and fourth stile326may define a third opening334of the panel300. In such embodiments, the panel300may include a first inset panel340secured within the first opening330of the frame302, a second inset panel342secured within the second opening332of the frame302, and a third inset panel344secured within the third opening334of the frame302. The first inset panel340, second inset panel342, and third inset panel344may be similar or may be configured differently. Each of the first inset panel340, second inset panel342, and the third inset panel344may be similar to the inset panel124ofFIGS.1-2, described above. For instance, each of the first inset panel340, second inset panel342, and third inset panel344may be one or more panes of glass, polymer, metal, natural material such as wood, or other material. In some embodiments, the first, second, and third inset panels340,342,344may be a transparent or translucent window, such as an insulated window. AlthoughFIGS.3-4illustrate panel300as including three openings, the panel300may include any number of openings, such as one opening, two openings, or greater than three openings. In addition, the stiles314may be spaced equidistantly along the first rail310and the second rail312as illustrated inFIGS.3-4, or the stiles314may be spaced unevenly along the first rail310and the second rail312to provide a desired opening size and/or configuration. The first rail310, second rail312, and stiles314may include many configurations. For example, the first rail310, the second rail312, and each of the first, second, third, and fourth stiles320,322,324,326may be hollow members, such as boxed frame members, hollow extrusions, or the like. In such embodiments, each of the first rail310, the second rail312, the first stile320, the second stile322, the third stile324, and the fourth stile326may include an internal cavity, which may run the length of the respective frame members304. In some embodiments, the frame members304may be secured together such that the respective internal cavities of the frame members304are in communication with one another. For example, the first, second, third, and fourth stiles320,322,324,326may be secured to the first rail310and the second rail312such that the entirety of the frame302is hollow, though other configurations are contemplated, such as the frame302being at least partially hollow (e.g., greater than 25% hollow, greater than 50% hollow, greater than 75% hollow, greater than 90% hollow, or the like). In this manner, one cavity may be created within the frame302once the frame members304are secured together. In some embodiments, multiple cavities may be created within the frame302once the frame members304are secured together. The frame members304may be secured together in many configurations. For instance, the first stile320may include opposing first and second ends360,362, the second stile322may include opposing third and fourth ends366, the third stile324may include opposing fifth and sixth ends368,370, and the fourth stile326may include opposing seventh and eighth ends372,374. In such embodiments, the first end360of the first stile320, the third end364of the second stile322, the fifth end368of the third stile324, and the seventh end372of the fourth stile326may be secured to the first rail310, such as via welding or other fastening methods. Similarly, the second end362of the first stile320, the fourth end366of the second stile322, the sixth end370of the third stile324, and the eighth end374of the fourth stile326may be secured to the second rail312, such as via welding or other fastening methods, which may be the same or different than the connections to the first rail310. The attachment of the first end360, the third end364, the fifth end368, and the seventh end372to the first rail310and the attachment of the second end362, the fourth end366, the sixth end370, and the eighth end374to the second rail312may be airtight. In this manner, the respective interfaces between the first rail310and each of the first stile320, second stile322, third stile324, and fourth stile326may seal the first rail310to the first stile320, second stile322, third stile324, and fourth stile326to allow for a vacuum to be created inside at least the first rail310, the first stile320, the second stile322, the third stile324, and the fourth stile326, or any combination thereof. Similarly, the respective interfaces between the second rail312and each of the first stile320, second stile322, third stile324, and fourth stile326may seal the second rail312to the first stile320, second stile322, third stile324, and fourth stile326to allow for a vacuum to be created inside at least the second rail312, the first stile320, the second stile322, the third stile324, and the fourth stile326, or any combination thereof. In some embodiments, the first rail310and the second rail312may be configured to accommodate the stiles314and/or facilitate the connection between the stiles314and the respective rail. For instance, as shown inFIG.4, the second rail312may include first, second, third, and fourth apertures380,382,384,386to accommodate the respective attachments of the first stile320, the second stile322, the third stile324, and the fourth stile326to the second rail312. For instance, the first aperture380may receive at least a portion of the second end362of the first stile320, the second aperture382may receive at least a portion of the fourth end366of the second stile322, the third aperture384may receive at least a portion of the sixth end370of the third stile324, and the fourth aperture386may receive at least a portion of the eight end of the fourth stile326, or any combination thereof, for attachment of the first, second, third, and fourth stiles320,322,324,326to the second rail312. In some embodiments, the apertures may fluidically connect the internal cavities of the stiles and rails. For instance, the first aperture380may fluidically connect the internal cavities of the first stile320and the second rail312, the second aperture382may fluidically connect the internal cavities of the second stile322and the second rail312, the third aperture384may fluidically connect the internal cavities of the third stile324and the second rail312, and the fourth aperture386may fluidically connect the internal cavities of the fourth stile326and the second rail312, or any combination thereof. The first rail310may be configured similarly to the second rail312for attachment of the first, second, third, and fourth stiles320,322,324,326to the first rail310. In some embodiments, the ends of the stiles314may be sized and/or shaped to facilitate attachment of the stiles314to the rails310,312. For instance, as shown inFIG.4, each of the first end360and the second end362of the first stile320may include a tab390for connection with the first rail310and the second rail312to define respective terminal ends of the first rail310and the second rail312. Similarly, each of the seventh end372and the eighth end374of the fourth stile326may include a tab392for connection with the first rail310and the second rail312to define respective opposite terminal ends of the first rail310and the second rail312. Such examples are illustrative only, and the ends of the stiles314may be attached to the rails310,312in other suitable configurations that seal the frame members304together and allow for a vacuum to be created inside the frame302. FIG.5illustrates a front perspective view of the panel300with an air evacuation path500in accordance with an embodiment of the disclosure. In embodiments, once the frame members304of the panel300are secured together, one or more internal cavities of the frame302may be evacuated and sealed to create a vacuum insulated panel section. For instance, at least portions of the frame302may be vacuum insulated to provide an insulation characteristic of the frame302, such as limiting one or more convection and/or conduction heat paths through the frame302. In this manner, the panel300may form at least a portion of an insulated door or other covering (e.g., garage door, storefront, etc.). The vacuum insulated characteristic of the panel300may reduce material costs and/or weight associated with other insulated methods. For example, conventional foam insulation may be omitted from the vacuum insulated panel to reduce weight and manufacturing costs. This may reduce the size of springs and other hardware needed to lift or support the panel300. In addition, a fully sealed construction may reduce air leakage across the panel300, further increasing an insulating efficiency of the panel300. This may save energy costs and make an associated room more comfortable. As shown, a vacuum502may be connected to the panel300, such as at a vacuum connection504defined in the first rail310adjacent to the fourth stile326, although other configurations are contemplated, including multiple vacuum connections504, a connection at another portion of the panel300, or enclosing part or all of the panel300inside a vacuum chamber. Once the vacuum502is connected to the panel300, the internal cavitiy(ies) of the frame302are evacuated of air, after which the vacuum connection(s)504is/are sealed to create a vacuum insulated panel. FIG.5Billustrates a front perspective view of the panel300with an air purging path550in accordance with an embodiment of the disclosure. In embodiments, one or more of frame members304may be filled with a low conductivity gas to provide an insulation characteristic of panel300and/or frame302. For example, once the frame members304of panel300are secured together, the frame302may be filled with low conductivity gas and sealed to create an insulated panel section. In some embodiments, each frame member304may be filled with low conductivity gas and sealed independently. The low conductivity gas may be any gas having a thermal conductivity less than atmospheric air. For instance, the low conductivity gas may be argon gas, krypton gas, xenon gas, an argon/krypton blend, an argon/nitrogen blend, or any other gas or gas mixture producing an R-value better than atmospheric air. In some implementations, the thermal conductivity of atmospheric air is about 26.2 mW/(m·K) at 25 degrees Celsius. Accordingly, in some implementations, the thermal conductivity of the low conductivity gas may be in the range of about 2 to about 25.5 mW/(m·K) at 25 degrees Celsius. In some implementations, the range of suitable thermal conductivities of the low conductivity gas is about 4.59 mW/(m·K) to 5.61 mW/(m·K) at 25 degrees Celsius, 7.92 mW/(m·K) to 9.68 mW/(m·K) at 25 degrees Celsius, 14.4 mW/(m·K) to 17.6 mW/(m·K) at 25 degrees Celsius, or 22.8 mW/(m·K) to 25.2 mW/(m·K) at 25 degrees Celsius. Similar to the vacuum-insulated panel300ofFIG.5A, the gas-filled panel300ofFIG.5Bmay reduce material costs and/or weight associated with other insulated methods. For example, conventional foam insulation may be omitted to reduce weight and manufacturing costs. This may reduce the size of springs and other hardware needed to lift or support the panel300. In addition, a gas-filled frame may increase an insulating efficiency of the panel300, saving energy costs and making an associated room more comfortable. As shown, the frame members304and/or frame302may be filled with low conductivity gas using an air purging system552. Air purging system552may include a gas source560(e.g., an argon gas source, a low conductivity gas source, etc.) providing a low conductivity gas to fill panel300or frame members304, either collectively or individually. For example, low conductivity gas may be provided by gas source560at a fill connection562. In embodiments, panel300or frame members304may be purged of atmospheric air. For example, atmospheric air may be first removed from panel300/frame members304and replaced with low conductivity gas. In some embodiments, panel300/frame members304may include a release valve564allowing air to be released from panel300/frame members304as low conductivity gas is filling panel300/frame members304. Depending on the application, the air released from panel300/frame members304(e.g., via release valve564) may be vented to atmosphere or collected by an air collection system570. FIG.6illustrates a flow diagram of a process600of assembling a multi-panel covering for an architectural opening in accordance with an embodiment of the disclosure. It should be appreciated that any step, sub-step, sub-process, or block of process600may be performed in an order or arrangement different from the embodiments illustrated byFIG.6. For example, one or more blocks may be omitted from or added to the process600. Although process600is described with reference to the embodiments ofFIGS.1-5, process600may be applied to other embodiments. In block602, process600may include manufacturing a plurality of rails and a plurality of stiles for a panel frame. The rails may be similar to the first rail310and second rail312ofFIGS.3-4, described above. The stiles may be similar to the first stile320, second stile322, third stile324, and fourth stile326ofFIGS.3-4, described above. The panel frame may be similar to the frame302ofFIGS.3-5, described above. The rails and stiles may be manufactured via many methods and in many configurations. For example, the rails and stiles may be extruded from aluminum, stainless steel, or other metal in many profile shapes. Depending on the application, the rails and stiles may be manufactured in-house or may be purchased from a third-party manufacturer. In some embodiments, the rails and stiles may be off-the-shelf components or otherwise readily available in the market. In block604, process600includes assembling the plurality of rails to the plurality of stiles to define at least one opening of the panel frame. For instance, the first rail310and second rail312may be secured to the first stile320, second stile322, third stile324, and fourth stile326ofFIGS.3-4, described above, such that various openings are defined in the panel frame. The rails may be assembled to the stiles in many configurations. For instance, the rails and stiles may be welded together, bolted together, molded together, or the like. In some embodiments, the rails and stiles may be placed in an assembly jig to assure proper assembly and alignment. Depending on the application, the rails and stiles may be assembled by hand, assembled via an automated process, or any combination thereof. In block606, process600includes sealing the interfaces between the plurality of rails and the plurality of stiles. In some embodiments, the interfaces may be sealed via the assembly process itself. For instance, sealing the interfaces may including welding the plurality of rails to the plurality of stiles. Depending on the application, the interfaces may be welded by hand or via an automated assembly (e.g., robotic welding). In some embodiments, the interfaces may be sealed using one or more additional components between the rails and stiles. For instance, a sealing element (e.g., O-ring, elastomeric material, etc.) may be placed between the rails and stiles to seal the interfaces and allow the panel frame to be vacuum sealed. In block608, process600includes evacuating air from an interior space of the panel frame. For instance, once the interfaces between the plurality of rails and the plurality of stiles are sealed, the panel frame may be connected to a vacuum or placed in a vacuum chamber and at least a portion of the panel frame may be vacuum insulated. For example, one or more internal cavities of the panel frame may be evacuated of air by vacuum. Once the internal cavity(ies) of the panel frame are evacuated of air, the vacuum connections may be sealed. In block610, process600may include finishing the panel frame after the panel frame is vacuum insulated. For instance, the panel frame may be powder coated or anodized, although other finishing options are contemplated, including painting, clear coated, or the like. Finishing the panel frame after the panel frame is assembled and vacuum insulated reduces the likelihood of the finish being damaged during assembly. This reduces scrap and rework costs and improves customer satisfaction with the panel frame. In block612, process600includes inserting a panel member within each opening of the panel frame. The panel member may be similar to the member ofFIGS.1-2or the first inset panel340, second inset panel342, and third inset panel344ofFIGS.3-4, described above. For instance, the panel member may be a transparent or translucent window. In some embodiments, the window may include insulation characteristics itself, such as including multiple panes of glass, with the spaces between the panes turned into a vacuum or filled with gas with a lower thermal conductivity and heat capacity than “air.” The panel member may be secured within the opening in many configurations. For instance, the panel member may be clipped to the panel frame, sealed to the panel frame, secured to the panel frame via mechanical fasteners, inserted within a receiving groove defined within the panel frame, among others. In block614, process600may include assembling a plurality of panel frames together to define a multi-panel covering. For instance, a plurality of panel frames may be hingedly connected to define a retractable multi-panel garage door, storefront, or the like. In such embodiments, the multiple panel frames may be secured together via one or more hinges. The hinges may be similar to the hinges140ofFIG.2, described above. For instance, the hinges may allow the multi-panel covering to articulate as the covering is moved between positions, such as to enable movement of the covering along a track between a vertical (closed) position and a horizontal (open or overhead) position. FIG.7illustrates a flow diagram of a process700of assembling a panel frame of a covering for an architectural opening in accordance with an embodiment of the disclosure. It should be appreciated that any step, sub-step, sub-process, or block of process700may be performed in an order or arrangement different from the embodiments illustrated byFIG.7. For example, one or more blocks may be omitted from or added to the process700, such as adding one or more blocks of process600, described above. Although process700is described with reference to the embodiments ofFIGS.1-6, process700may be applied to other embodiments. In block704, process700includes connecting first frame members (e.g., rails) to second frame members (e.g., stiles) to define at least one opening of a panel frame. For instance, the first rail310and second rail312may be secured to the first stile320, second stile322, third stile324, and fourth stile326ofFIGS.3-4, described above, such that various openings are defined in the panel frame. The frame members may be connected in many configurations. For instance, the frame members may be welded together, bolted together, molded together, or the like. In embodiments, the first frame members may be connected to the second frame members at respective interfaces to define at least one opening of a panel frame. In embodiments, block704may include positioning ends of the first frame members at least partially within respective apertures defined in the second frame members, as described above. The apertures may fluidically connect internal cavities of the frame members. In block706, process700includes sealing the interfaces between the first frame members and the second frame members. In embodiments, the interfaces may be sealed via the assembly process itself. For instance, sealing the interfaces may including welding the first frame members (e.g., rails) to the second frame members (e.g., stiles). In embodiments, the interfaces may be sealed using one or more additional components between the frame members, such as a sealing element (e.g., O-ring, elastomeric material, etc.) placed between the frame members to seal the interfaces. In block708, process700includes filling the internal cavities of each frame member with a gas having a thermal conductivity less than atmospheric air. In embodiments, block708may include purging atmospheric air from the internal cavity of each frame member, and sealing the internal cavity of each frame member independently. In embodiments, block708may include filling the panel frame with low conductivity gas once assembled. In block712, process700includes inserting an inset panel within the at least one opening of the panel frame. The inset panel may be similar to the member ofFIGS.1-2or the first inset panel340, second inset panel342, and third inset panel344ofFIGS.3-4, described above. For instance, the inset panel may be a transparent or translucent window, an insulated panel, a corrugated steel panel, a plastic panel, or the like. In some embodiments, the inset panel may include insulation characteristics itself, such as including multiple panes of glass, with the spaces between the panes turned into a vacuum or filled with gas with a lower thermal conductivity and heat capacity than air. The inset panel may be secured within the opening in many configurations. For instance, the panel member may be clipped to the panel frame, sealed to the panel frame, secured to the panel frame via mechanical fasteners, inserted within a receiving groove defined within the panel frame, etc. Embodiments described above illustrate but do not limit the invention. It should also be understood that numerous modifications and variations are possible in accordance with the principles of the invention. Accordingly, the scope of the invention is defined only by the following claims. | 33,209 |
11859441 | DETAILED DESCRIPTION The following detailed description is merely exemplary in nature and is not intended to limit the present disclosure or the application and uses of the present disclosure. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description. Broadly, example embodiments disclosed herein include a fenestration unit, such as a window unit, having a frame that includes a weep drainage system. The system may include an internal drainage path that is defined from a corner member of the frame to a weep outlet opening defined on the exterior of the fenestration unit. In some embodiments, the system may include a corner component (e.g., a corner key) and cladding. The corner component may include a reservoir and a fluid outlet from the reservoir to define part of a fluid path. The cladding may also include at least one aperture that is coupled to the fluid outlet of the corner component, and the cladding may also include a weep outlet for the water to drain from the weep drainage system. As will be discussed, the weep drainage system of the present disclosure provides effective moisture drainage. The weep drainage system may provide a low-profile, compact, and inconspicuous arrangement for moisture to drain from the fenestration unit. The fenestration unit may also be structurally robust. Furthermore, one or more features of the present disclosure may provide manufacturing benefits, such as lower part count, increased manufacturing efficiency, and/or other advantages. Referring now toFIG.1, a fenestration unit104is shown according to example embodiments of the present disclosure. The fenestration unit104may include features that direct water, droplets of water, rainwater, sleet and snow runoff, water from sprinkler systems, and/or other moisture away and outward from the unit104. In some embodiments, the fenestration unit104may be configured as and/or combined with a horizontally sliding window unit103, and the majority of the discussion will refer to the fenestration unit104as such. However, it will be appreciated that one or more features of the present disclosure may be configured for a horizontally sliding door or another type of fenestration unit104without departing from the scope of the present disclosure. Also, in some embodiments, the fenestration unit104may be a clad window as will be discussed in detail below; however, the fenestration unit104may have a different configuration without departing from the scope of the present disclosure. As shown inFIG.1, the fenestration unit104may include a frame110that supports a first panel112and a second panel113. At least one of the panels112,113may be a sliding panel that is supported within the frame110for sliding movement along a lateral axis126(i.e., lateral direction). In some embodiments, the first panel112may be a fixed, non-active panel that is fixedly supported within the frame110, whereas the second panel113may be a horizontally sliding panel that is supported for sliding movement along the axis126. (A vertical axis125and an interior/exterior axis127are also indicated inFIG.1for reference purposes.) The panels112,113may be supported within the frame110and may be offset along the interior/exterior axis127such that the second panel113may slide and overlap the first panel112as the second panel113opens. The second panel113may also move to a closed position, as shown, in which the panels112,113are non-overlapping and are spaced apart along the lateral axis126. As shown inFIG.1, the frame110may be rectangular and may generally include a header111, a first jamb115, a second jamb117, and a sill114. The header111and sill114may extend along the lateral axis126and may be separated along the vertical axis125. The first and second jambs115,117may extend along the vertical axis125and may be separated along the lateral axis126. As shown inFIG.2, at least part of the vertically-extending first jamb115and at least part of the horizontally-extending sill114may be joined at a corner joint120. It will be appreciated that the second jamb117may be joined to the opposite end of the sill114with a corner joint similar to the corner joint120described herein. The corner joint120may include a corner key118, such as the corner key118shown inFIGS.2-5according to example embodiments. The corner key118may include a substantially block-shaped base130(FIGS.3and4), which includes a first lateral face132, a second lateral face134, an exterior end136, an interior end138, a top side140, and a bottom side142. The corner key118may also include one or more flanges144that extend vertically from the margin of the top side140. The corner key118may also include a number of features (e.g., projections, pockets, bolt holes, fastener seats, etc.) for attaching to adjacent members of the frame110. The corner key118may further include features that increase stiffness, strength, and robustness of the corner key118. The corner key118may also include one or more features for collecting moisture and directing it away from the fenestration unit104as will be discussed. In some embodiments, the corner key118may be formed of a polymeric material. In some embodiments, the corner key118may be an injection molded part. However, the corner key118may be made from different material and/or may be formed in other ways without departing from the scope of the present disclosure. As shown inFIGS.2and6, the first lateral face132of the corner key118may abut against and fixedly attach to a longitudinal end of a sill member146of the sill114. The sill member146may be an elongate member that extends horizontally and linearly along the lateral axis126. The sill member146may, in some embodiments, be a lineal extruded member of the sill114. The sill member146may be constructed from and/or include vinyl, fiberglass, aluminum, and/or other material. The sill member146may be strong and stiff and may include a number of relatively thin walls that run along the lateral axis126and that match at least part of the profile of the first lateral face132of the corner key118. Accordingly, at least some of the gaps, spaces, etc. in the lateral face132(e.g., those shown inFIG.2) may be open to and may be continuous with corresponding gaps, spaces, etc. extending along the sill member146along the lateral axis126. In some embodiments, the sill member146may be fixedly attached to the corner key118via fasteners, adhesives, and/or other attachments. Moreover, as represented inFIG.2, the top side140of the corner key118may abut against and fixedly attach to a longitudinal end of a jamb member150(shown in phantom). The jamb member150may be an elongate member that extends vertically and linearly along the vertical axis125. The jamb member150may, in some embodiments, be a lineal extruded member of the jamb115. The jamb member150may be constructed from and/or include vinyl, fiberglass, aluminum, and/or other material. In some embodiments, the jamb member150may be fixedly attached to the corner key118via fasteners, adhesives, and/or other attachments. As stated, the fenestration unit104may be configured as a clad window (i.e., cladded window, wood-clad window, etc.). As such, the fenestration unit104may additionally include a cladding152as shown inFIGS.1and6. The cladding152may include one or more plate- or strip-like segments that extend about and frame the exterior of the fenestration unit104. The cladding152may be made of a strong material, such as metal in some embodiments. The cladding152may be made of aluminum alloy in some embodiments. The cladding152may be a lineal extruded part in some embodiments. The cladding152may include a first cladding segment, referred to herein as an apron segment154, and a second cladding segment, referred to herein as a jamb segment156. The jamb segment156may extend vertically along the vertical axis125and may cover over the jamb member150and part of the corner key118. The apron segment154may extend horizontally along the lateral axis126and may cover over the sill member146and part of the corner key118. The apron segment154and jamb segment156may, in some embodiments, include respective terminal ends that are cut on a bias angle relative to the respective longitudinal axis. As shown inFIG.1, these terminal ends may abut to cooperatively define a seam158in the cladding152. FIGS.6-8represent the apron segment154according to example embodiments. The apron segment154may be a unitary, one-piece member. The apron segment154may be a lineal extruded part. The apron segment154may include a sill cover portion160, an apron plate portion162that depends from the sill cover portion160along the vertical axis125, and a projecting portion164that projects outward along the interior/exterior axis127from the sill cover portion160. The sill cover portion160may include a generally C-shaped cross section as shown inFIG.7and may receive and cover the exterior end136of the corner key118. The sill member146may continue the profile of the exterior end136further along the lateral axis126and the sill cover portion160may cover over and clad this portion of the sill member146as well. The apron plate portion162may extend downward vertically to cover over the portion of the wall below the fenestration unit104. The projecting portion164may include a first projecting wall170and a second projecting wall172that project outward from the sill cover portion160. Both the first and second projecting walls170,172may have relatively small wall thicknesses. The first projecting wall170may be flush and continuous with the top surface of the sill cover portion160, and an exterior terminal edge of the first projecting wall170may be bent downward. The second projecting wall172may be spaced apart downwardly from the first projecting wall170along the vertical axis125. The second projecting wall172may split into multiple (e.g., two) branches as it projects further from the cover portion160. The fenestration unit104further includes a weep drainage system180(FIG.7). Generally, the weep drainage system180may define a fluid path182defined from the frame corner key118and through the cladding152to drain away from the fenestration unit104under force of gravity. The corner key118may define features of the weep drainage system180. In some embodiments, the corner key118may include at least one reservoir184of the drainage system180. The reservoir may be recessed into the lateral face132along the lateral axis126. Also, the reservoir184may extend along the interior/exterior axis127. The reservoir184may be configured to receive and collect fluid (e.g., rainwater, snow runoff, etc.). For example, moisture in the jamb115may move into and collect in the reservoir184. Also, moisture in the sill member146and/or other portions of the sill114may move into and collect in the reservoir184. In some embodiments, the reservoir184may be tilted slightly toward the exterior such that the moisture moves toward the exterior end136of the corner key118under force of gravity. The corner key118may further include a projection186that defines a corner key fluid outlet188of the weep drainage system180. The projection186may project outward along the interior/exterior axis127. The projection186may be a rectangular, hollow, and tubular. The corner key fluid outlet188may extend along the projection186through the projection186. The corner key fluid outlet188may be fluidly connected to the reservoir184. Accordingly, fluid in the reservoir184may flow to the corner key fluid outlet188and outward from the corner key118. The cladding152may also define features of the weep drainage system180. In some embodiments, the cladding152may include at least one aperture190(FIGS.6-8) for the corner key fluid outlet188. The aperture190may be a notch, slot, or other opening on one end of the apron segment154(FIG.8) and may be formed in the sill cover portion160. The aperture190may correspond in shape to the projection186of the corner key118. The aperture190may receive the projection186. In some embodiments, the apron segment154may fit within a gap191(FIG.5) defined between the projection186and an adjacent flange197of the corner key118. The jamb segment156of the cladding152may also abut against the apron segment154and close off the open end of the aperture190in the apron segment154. The cladding152may further include a weep outlet199. The weep outlet199may be a slot that extends along the lateral axis126and may be defined between the first projecting wall170and the second projecting wall172. Accordingly, the corner key fluid outlet188may be received in the aperture190of the cladding152and may be disposed and substantially hidden between the first and second projecting walls170,172of the apron segment154of the cladding152. The weep drainage system180may also include a sealing member195(FIGS.6and7). The sealing member195may be a cured sealant. The sealing member195may be a thin layer of sealant disposed between the cladding152and the projection186of the corner key, within the gap191, and proximate the aperture190. In some embodiments, the projection186may include a barrier wall185that projects laterally therefrom, and the barrier wall185may be shaped to direct uncured sealant as it flows around the aperture190to form the sealing member195. Accordingly, the sealing member195may fluidly seal this area and ensure moisture flows out of the fenestration unit104as discussed. The fenestration unit104may further include a sealing injection aperture198. As shown inFIGS.4and5, the corner key118may include the sealing injection aperture198, which may be a through-hole at the bottom side142. When assembled, the aperture198may provide access to the gap191from the exterior of the unit104. Fluid sealant may be injected into the aperture198, and the barrier wall185and other surrounding surfaces may direct the sealant so that it flows into the gap191and around the aperture190. Then, the sealant may be cured to form the sealing member195. In some embodiments, to manufacture the fenestration unit104, the segments of the cladding152may be extruded. The sill member146and the jamb member150may be extruded as well. The ends of these extruded members may be mitered as needed. The corner key118may be formed via injection molding in some embodiments. Furthermore, the aperture190may be formed in the apron segment154of the cladding152, for example, by cutting material away, by punching through the material, or otherwise. For assembly, the apron segment154of the cladding152may be attached to the sill member146, for example, by sliding along the lateral axis126, by snap-on fitting, using fasteners, or otherwise. Then, the corner key118may be attached to the sill member146using fasteners, adhesives, and/or other attachments. When attaching the corner key118, the projection186may be fitted within the aperture190. Next, the jamb member150may be attached to the corner key118using fasteners, adhesives, and/or other attachments. Also, the jamb segment156of the cladding152may be attached to the jamb member150(by snap-on fit, slide-on fit, and/or other attachments). Subsequently, sealant may be injected into the aperture198, and the injected sealant may be cured to form the sealing member195. These manufacturing methods may be highly efficient, with relatively low part count, low costs, etc. During use of the fenestration unit104, fluid may move into and briefly collect within the reservoir184. This moisture may flow along the fluid path182from the reservoir184of the frame corner key, through the corner key fluid outlet188, through the aperture190, and into the weep outlet199to drain from the fenestration unit. This weep drainage system180may be highly effective for removing moisture from the fenestration unit104. The drainage system180may be very inconspicuous as well, even in a low-profile fenestration unit104of the type illustrated. Indeed, the system180is largely hidden inside the fenestration unit104. Also, the weep outlet199is a small, inconspicuous opening that is integral to the cladding152. Furthermore, the following examples are provided: In an example, a fenestration unit is disclosed that includes a frame corner key that includes a corner key fluid outlet. The fenestration unit also includes a cladding having an aperture for the corner key fluid outlet. Furthermore, the fenestration unit includes a weep drainage system with a fluid path defined from the frame corner key, through the corner key fluid outlet, and through the aperture to drain from the fenestration unit. In an option, the frame corner key includes a projection, and the aperture receives the projection. The corner key fluid outlet extends along the projection. In an additional option, the projection is hollow and tubular with the corner key fluid outlet extending therethrough. In an additional option, the fenestration unit further includes a sealing member that seals between the frame corner key and the cladding, proximate the aperture. In an additional option, the frame corner key includes a projection, and the aperture receives the projection. The corner key fluid outlet extends along the projection. The sealing member extends within a gap between the projection and the cladding, proximate the aperture. Moreover, in an additional option, the corner key includes a sealant injection aperture that provides fluid access to the gap from outside the fenestration unit. In an addition option, the corner key includes a reservoir configured to collect fluid. The fluid path is defined from the reservoir, through the corner key fluid outlet, and through the aperture to drain from the fenestration unit. Furthermore, in an additional option, the cladding includes an apron segment with the aperture, the aperture being open at one end of the apron cladding segment. In an additional option, the cladding includes an apron segment that defines at least part of the aperture and that includes a weep outlet. The fluid path is defined from the frame corner key, through the corner key fluid outlet, through the aperture, and through the weep outlet to drain from the fenestration unit. Also, in an additional option, the fenestration unit includes a frame sill member. The apron segment includes a cover portion that at least partly covers the frame sill member and the frame corner key. The apron segment includes a first projecting wall and a second projecting wall that project from the cover portion. The aperture is included in the cover portion, and the weep outlet is defined between the first and second projecting walls. In an additional example, a method of manufacturing a fenestration unit is disclosed. The method includes providing a frame corner key with a corner key fluid outlet. The method also includes attaching a cladding to the frame corner key. The cladding has an aperture for the corner key fluid outlet to define at least part of a weep drainage system with a fluid path defined from the frame corner key, through the corner key fluid outlet, and through the aperture to drain from the fenestration unit. In an option, the method includes receiving a projection of the frame corner key within the aperture. The corner key fluid outlet extends along the projection. In an additional option, the projection is hollow and tubular with the corner key fluid outlet extending therethrough. In an additional option, the method further includes providing a sealing member that seals between the frame corner key and the cladding, proximate the aperture. In an additional option, the frame corner key includes a projection. The corner key fluid outlet extends along the projection. The method further includes receiving the projection within the aperture. The method also includes extending the sealing member within a gap between the projection and the cladding, proximate the aperture. In an additional option, the method further includes injecting sealant into the gap via a corner key sealant injection aperture providing fluid access to the gap from outside the fenestration unit. The method also includes curing the sealant after injecting the sealant. In an additional option, the method includes providing the corner key with a reservoir configured to collect fluid. The fluid path is defined from the reservoir, through the corner key fluid outlet, and through the aperture to drain from the fenestration unit. In an additional option, the cladding includes an apron segment that defines at least part of the aperture and that includes a weep outlet. The fluid path is defined from the frame corner key, through the corner key fluid outlet, through the aperture, and through the weep outlet to drain from the fenestration unit. In an additional option, the method further includes providing a frame sill member. The apron segment includes a cover portion. The method further includes at least partly covering the frame sill member and the frame corner key with the cover portion. The apron segment includes a first projecting wall and a second projecting wall that project from the cover portion. The aperture is included in the cover portion, and the weep outlet is defined between the first and second projecting walls. In a further example, a sliding window unit is disclosed that includes a sill member, a jamb member, and a fenestration unit comprising a frame corner key that includes a corner key fluid outlet, a cladding having an aperture for the corner key fluid outlet, and a weep drainage system with a fluid path defined from the frame corner key, through the corner key fluid outlet, and through the aperture to drain from the fenestration unit. The frame corner key attaches the sill member and the jamb member, the frame corner key including a reservoir and a projection that defines the corner key fluid outlet. The cladding is provided as an apron cladding segment that is attached to and that covers over at least part of the sill member, the apron cladding segment having the aperture that receives the projection of the frame corner key, the apron cladding segment having a weep outlet. The weep drainage system with the fluid path is defined from the reservoir and to the weep outlet to drain from the fenestration unit. In an example, the sliding window unit is provided in combination with any of the above mentioned examples and options of the fenestration unit. For example, the sliding window unit is combined with the fenestration unit. For example, the sliding window unit is combined with the fenestration unit wherein the frame corner key includes a projection, and the aperture receives the projection, the corner key fluid outlet extending along the projection. For example, the sliding window unit is combined with the fenestration unit wherein the projection is hollow and tubular with the corner key fluid outlet extending therethrough. For example, the sliding window unit is combined with the fenestration unit further comprising a sealing member that seals between the frame corner key and the cladding, proximate the aperture. For example, the sliding window unit is combined with the fenestration unit wherein the frame corner key includes a projection and the aperture receives the projection, the corner key fluid outlet extending along the projection. The sealing member extends within a gap between the projection and the cladding, proximate the aperture. For example, the sliding window unit is combined with the fenestration unit wherein the corner key includes a sealant injection aperture that provides fluid access to the gap from outside the fenestration unit. For example, the sliding window unit is combined with the fenestration unit wherein the corner key includes a reservoir configured to collect fluid, and wherein the fluid path is defined from the reservoir, through the corner key fluid outlet, and through the aperture to drain from the fenestration unit. For example, the sliding window unit is combined with the fenestration unit wherein the cladding includes an apron segment with the aperture, the aperture being open at one end of the apron cladding segment. For example, the sliding window unit is combined with the fenestration unit wherein the cladding includes an apron segment that defines at least part of the aperture and that includes a weep outlet; and the fluid path is defined from the frame corner key, through the corner key fluid outlet, through the aperture, and through the weep outlet to drain from the fenestration unit. For example, the sliding window unit is combined with the fenestration unit further comprising a frame sill member; wherein the apron segment includes a cover portion that at least partly covers the frame sill member and the frame corner key; the apron segment includes a first projecting wall and a second projecting wall that project from the cover portion; and the aperture is included in the cover portion, and the weep outlet is defined between the first and second projecting walls. In a further example, a sliding window unit is disclosed that includes a sill member, a jamb member, and a frame corner key that attaches the sill member and the jamb member. The frame corner key includes a reservoir and a projection that defines a corner key fluid outlet. The sliding window unit includes an apron cladding segment that is attached to and that covers over at least part of the sill member. The apron cladding segment has an aperture that receives the projection of the frame corner key. The apron cladding segment has a weep outlet. The window unit also includes a weep drainage system with a fluid path defined from reservoir, through the corner key fluid outlet, through the aperture, and to the weep outlet to drain from the fenestration unit. While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the present disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the present disclosure. It is understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the present disclosure as set forth in the appended claims. | 26,647 |
11859442 | DETAILED DESCRIPTION OF THE INVENTION The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Those of ordinary skill in the art realize that the following descriptions of the embodiments of the present invention are illustrative and are not intended to be limiting in any way. Other embodiments of the present invention will readily suggest themselves to such skilled persons having the benefit of this disclosure. Like numbers refer to like elements throughout. Although the following detailed description contains many specifics for the purposes of illustration, anyone of ordinary skill in the art will appreciate that many variations and alterations to the following details are within the scope of the invention. Accordingly, the following embodiments of the invention are set forth without any loss of generality to, and without imposing limitations upon, the claimed invention. In this detailed description of the present invention, a person skilled in the art should note that directional terms, such as “above,” “below,” “upper,” “lower,” and other like terms are used for the convenience of the reader in reference to the drawings. Also, a person skilled in the art should notice this description may contain other terminology to convey position, orientation, and direction without departing from the principles of the present invention. Furthermore, in this detailed description, a person skilled in the art should note that quantitative qualifying terms such as “generally,” “substantially,” “mostly,” and other terms are used, in general, to mean that the referred to object, characteristic, or quality constitutes a majority of the subject of the reference. The meaning of any of these terms is dependent upon the context within which it is used, and the meaning may be expressly modified. An embodiment of the invention, as shown and described by the various figures and accompanying text, provides a reinforce pet door system that may include a pet travel door301, illustratively shown inFIGS.3and4, a door panel303with an integrated pet travel door301, illustratively shown inFIG.3, and a security panel502as illustratively shown inFIG.5. The pet travel door301may comprise of a number of different types of pet travel doors, for example, without limitation, sliding, single flap, partitioned flap, magnetized bottom flap, magnetized sliding, or other pet travel door as understood by those skilled in the art that may be used. The pet travel door301may comprise of a number of different materials including, but not limited to, polycarbonate, plastic, metal, or ceramic. Those skilled in the art will notice and appreciate that a number of different pet travel doors and materials may be used as the pet travel door301while still accomplishing all the goals, features, and advantages of the present invention. Referring initially toFIGS.1A and1B, an embodiment of the pet door system according to the present invention is now described. This embodiment of the pet door system is directed to a door100having an integrated pet travel door301. The integrated pet travel door301is preferably configured to be installed into a main body member101of a door100. The main body member101may include a number of door panels105where the pet travel door301may be installed into. The pet travel door301is preferably installed in the lowest door panel105of the main body member101, as illustrated in the appended drawings. Those skilled in the art, however, will appreciate that should it be desired, the pet travel door301may be installed anywhere on the main body member101of the door100. For example, if so desired, the pet travel door may be installed on an upper panel of the door100, or off set from a central vertical line of the door. However, it is preferable, from both a functional and an aesthetic perspective, to provide the pet travel door301installed in the lower panel105of the main body member101of the door100. Now referencingFIGS.2,3, and3A, another embodiment of the present invention directed to a door panel303having an integrated pet travel door301installed therein. The door panel303having the integrated pet travel door301installed therein may be provided to be installed into a door. For example, a door manufacturer may install the door panel303having the integrated pet travel door301into an existing door where a panel105may have been otherwise located. The pet travel door301may be installed into a body member201of the door panel303. The body member201of the door panel303that has the pet travel door301installed therein may be installed into a main body member101of a door100that has a portion or all of one of its door panels105removed. Those skilled in the art will appreciate that it contemplated that the door panel105may be removed after manufacture of the door100to allow for installation of the door panel303in the door100, or that the door100may be manufactured without the door panel105to similarly allow for installation of the door panel303having the integrated pet door301according to the present invention. The main body member101that the body member201is installed into may not require that a door panel105is removed and may only require removing a portion of the main body member101so that the door panel201may be matingly installed into the main body member101. Those skilled in the art will also appreciate that the door panel303having the integrated pet travel door301may also be installed into a door100that does not include door panels. In such a case, it is contemplated that a passageway will be formed in the door100to accommodate installation of the door panel303having the pet travel door301integrated therein. The body member201may comprise of a number of different insulating and non-insulating materials. The insulating materials that may be used as the body member201may be, without limitation, fiberglass, expanded polystyrene, polyurethane, mineral wool, cellulose, E-glass reinforced fiberglass, S-glass reinforced fiberglass, aramid reinforced fiberglass, carbon reinforced fiberglass, and other materials as recognized by those skilled in the art to be used as and/or in the body member201of an embodiment of the present invention. Moreover, as mentioned further below, the body member201may comprise of a door panel that was cut out of a door during the manufacturing process of said door. Door panels that are cut out of a door during the manufacturing process are generally discarded and eventually located in a land fill with other construction waste and debris. The present invention can advantageously repurpose that which would have been wasted or environmentally unfriendly trash/debris, and using it to carry out the goals, features and advantages of the present invention. Therefore, the present invention is environmentally friendly and helps to reduce waste. Continuing to referenceFIG.3A, the door panel105that is a separate object from a main body member101(such as body member201), or a door panel that is monolithically formed a part of a main body member101(such as one of the door panels105in the main body member101as illustratively shown inFIGS.1A and1B) may include a passageway304that is formed through one face of the body member201(or door panel105) and out an opposite side/face. The passageway304may be sized to accommodate the size of the pet travel door301. Continuing with reference toFIGS.2,3and3A, the door panel may include body frame members202. The body frame members202may be affixed to an outer perimeter of the body member201of the door panel303, and on a perimeter of the passageway304of a main body member101. The passageway304may be configured to be a shape that may accommodate installation of the body member201that has the body frame members202affixed onto the outer perimeter of the body member201. The body frame members202may be used to provide a seal when the door panel303is installed into the main body member101of the door100to advantageously protect an interior of a structure from elements of weather, such as wind, water, and ice. The body frame members202may be made from steel, aluminum, plastic, composite, ceramics, or any other material or combination thereof as understood by those skilled in the art that may be used as a body frame member202. Those skilled in the art will notice and appreciate that a number of different materials may be used for the body frame member202while still accomplishing all the goals, features, and advantages of the present invention. FIG.4depicts an alternative pet travel door301that may be used in connection with the present invention. The pet travel door301illustrated inFIG.4illustratively includes a segmented door310. The segmented door310illustratively includes three segments. The three segments of the segmented door310are independently moveable with respect to one another. Accordingly, this may be advantageous for smaller animals that use the pet travel door301. The pet travel door301illustrated inFIG.4also includes framing302that is described in greater detail below. Now referring back toFIGS.1A,1B, and further toFIGS.4and12, a pet travel door301may include a pet travel door frame302that may be affixed to an outer perimeter of the pet travel door301and affixed to the passageway304that may be made in a body member201or a main body member101. The pet travel door frame302may include a pet travel door frame lock slot1203that is located at an upper portion of the pet travel door frame302. The pet travel door frame302may also include one or more pet travel door frame through channels1202that may be located at a lower portion of the pet travel door frame302. The pet travel door frame302may be made from plastic, composite, aluminum, steel, or any other material as understood by those skilled in the art to be used as a pet travel door frame302. Those skilled in the art will notice and appreciate that a number of different materials may be used as the pet travel door frame302while still accomplishing all the goals, features, and advantages of the present invention. Now referencingFIGS.5-9, an embodiment of the present invention may include a security panel502. The security panel502may be adapted to cover the pet travel door301on the outdoor and/or the indoor facing side of the pet travel door301. The security panel502may be adapted to cover the pet travel door301by placing the security panel502overlaying the pet travel door301. The security panel502may include a lock member104, a pair of post structural members901, a number of seal members501, a security panel body member102, and a reinforcement panel602. The security panel body member102may be a cutout of a door panel from a door, such as door panels removed from doors during the manufacturing process of the door that otherwise would be treated as a waste product may instead be repurposed to be used as the security panel body member102or the body member201for an embodiment of the present invention. Those skilled in the art will appreciate that this act of recycling decreases the environmental impact of the door manufacturing process and decreases the cost of creating an embodiment of the present invention. The security panel body member102may comprise of insulation materials to increase the security panel's502effectiveness at reducing elements of weather from passing through an embodiment of the present invention. The material of the security panel body member102may comprise of structural fiberglass such as, without limitation, E-glass reinforced fiberglass, S-glass reinforced fiberglass, aramid reinforced fiberglass, and carbon reinforced fiberglass or any material as understood by those skilled in the art that may be used as the security panel body member102. Those skilled in the art will notice and appreciate that the security panel body member102may comprise of a number of different materials while still accomplishing all the goals, advantages, and goals of the present invention. The reinforcement panel602may be affixed to a face on the security panel body member102, preferably a back-side face of the security panel body member102. The material used for the reinforcement panel602may be, without limitation, polycarbonate. Those skilled in the art will recognize that the reinforcement panel602may comprise of a number of different materials while still accomplishing all the goals, features, and advantages of the present invention. The reinforcement panel602may be adapted to cover the same area as the face of the security panel body member102that the reinforcement panel602is attached to. Those skilled in the art will appreciate that the frame302of the alternative pet travel door301illustrated inFIG.4may also be made of a polycarbonate material to provide enhanced reinforcement. The lock member104may be carried by a front face of the security panel body member102, and preferably at a top portion of the front face of the security panel body member102. The lock member104may include a locking arm601that may be attached to the lock member104. The lock member104may be rotatably movable between a locked position and an unlocked position. The locked position of the lock member104may be defined by the locking arm601being positioned to extend outwardly from the door and to engage a security panel body member lock slot701(discussed in greater detail below). The unlocked position of the lock member104may be defined by the locking arm601being rotatably positioned so as not to engage the security panel body member lock slot701. Those skilled in the art will notice and appreciate that a number of different types of locks may be implemented as the lock member104while still accomplishing all the goals, features, and advantages of the system. For example, without limitation, a padlock, a deadbolt, a lever handle, a cam lock, a euro profile cylinder, a mortise lock, a T-handle lock, a rim latch lock, a multi-point lock, a key-operated security lock, a closed shackle lock, a straight shackle lock, an open shackle padlock, a long shackle padlock, electronically operated locks, and many other lock types known by those skilled in the art may be used as the lock member104while still accomplishing all the goals, features, and advantages of the system. The lock member104may include a key lock801that is connected to the lock member104. The key lock801may be configured so that when the key lock801is in a locked position the lock member104is restricted from rotatably moving, and when the key lock801is not in the locked position the lock member104is unrestricted and is free to rotatably move. The security panel body member102may include a security panel body member lock slot701that may be configured to allow for movement of the locking arm601when the lock member104is in the locked and/or unlocked positions. Details for the lock member's104locking functions follow further below. Those skilled in the art will notice and appreciate that a verity of different types of locks may be used as the key lock801while still accomplishing all the goals, features, and advantages of the present invention. For example, without limitation, the key lock801may comprise of a combination lock, a touchscreen security lock, a proximity signal lock, a deadbolt, a fingerprint reader lock, a remote signal lock, a biometric scanner lock, and/or other types of locks as understood by those skilled in the art. Embodiments of the present invention may not have a key lock801included with the lock member104. Instead, some embodiments of the present invention may include a key lock801that is separate and not connected to the lock member104. The key lock801may instead be carried by the security panel body member102and/or the body member201. A key lock104that is not connected to the lock member104may include the same features and functionality as a key lock104that is connected to the lock member104as described herein. An embodiment of the present invention may also not include a key lock104as a component of the system so that the lock member104is the only component of the system with locking functionality, as illustratively shown inFIG.20. Such an embodiment of the present invention may be preferable when the embodiment includes a security panel502that is installed to cover the indoor facing side of the pet travel door301. Now additionally referencingFIG.10, the security panel502may include an upper security panel structural member1001and a lower security panel structural member1003. The upper security panel structural member1001may be attached to an upper portion of the security panel body member102. The upper security panel structural member1001may include an upper security panel structural member lock slot1002that is positioned to align with and allow for the rotatable movement of the locking arm601of the lock member104. The lower security panel structural member1003may be attached to a lower portion of the security panel body member102and may include one or more structural post members901(also illustrated inFIG.9) that may be affixed on a lower surface of the lower security panel structural member1003and may be oriented outwards. The structural post members901may be affixed to the lower security panel structural member1003or a part of the lower security panel structural member1003as a single monolithic unit. The lower security panel structural member1003may be in the shape of a “U” and configured to snugly form around the security panel body member102when affixed thereto. The lower security panel structural member1003may also be split into separate pieces, or the upper security panel structural member1001and the lower security panel structural member1003may be connected together as on single monolithic unit as illustratively shown inFIG.21. Those skilled in the art will recognize and appreciate that there are a number of different shapes and configurations that the upper security panel structural member1001and the lower security panel structural member1003can include while still accomplishing all the goals, features, and advantages of the present invention. Continuing with reference toFIGS.5-10, seal members501may be affixed to an outer perimeter of the security panel body member102to substantially cover the outer perimeter of the security panel body member102and may be positioned to overly the upper security panel structural member1001and the lower security panel structural member1003. Those skilled in the art will notice and appreciate that a number of materials and material combinations can be used for the seal members501while still accomplishing all the goals, features, and advantages of the present invention. The seal members501may include a grip member501aand a sealing lip501b, as illustratively shown inFIGS.13and14. The grip member501amay be used to hold the security panel502in place when the security panel502is installed to cover a pet travel door301when the pet travel door301is installed into a main body member101or a door panel303. The grip member501amay also act as an extra layer of sealant to keep weather elements from seeping past the security panel502when covering a pet travel door301. The sealing lip501bmay comprise entirely of, or in part, a flexible material similar to the material that the seal member501is made of, in whole or in part. The sealing lip501bmay be used as the main component to seal the elements from passing through the security panel502when the security panel is installed covering the pet travel door301. The seal members501may include, without limitation, a heterogeneous combination of polyvinyl chloride and a flexible material. The flexible material used may be a rubber, plastic, composite, or other material as understood by those skilled in the art to be used as a flexible material that can be used for all or a portion of the seal member501, the grip member501a, and/or the sealing lip501b. Continuing with to referenceFIG.10, and additionally referencingFIG.11, the seal member501that is located at the lower portion of the security panel body member102may contain a number of seal member through channels1103that are substantially aligned with the placement of the structural post members901on the lower security panel structural member1003. A seal member501that may be located at an upper portion of the security panel body member102may contain a upper security panel lock slot1104that is positioned to align with the locking arm601of the lock member104, and an arched cutout1102that may be located on one side of at least one of the seal members501that may be configured to accommodate the lock member104being carried by the security panel body member102without having the lock member104be positioned in conflict with the seal member501that may be closest to the lock member104when the lock member104is attached to the security panel body member102. Now referring toFIGS.17A and17B, an embodiment of the present invention may include a recess1510at a lower portion of the passageway304. In the embodiment of the invention directed to the door100having an integrated pet travel door301formed therein (illustrated inFIGS.1A and1B), the recess1510is formed in the body member101of the door100. Although the embodiment of the invention relating to the door100having the integrated pet door301does not show a passageway prior to the door panel being installed therein is shown, those skilled in the art will appreciate that the recess1510is formed in a lower portion of the door panel105. In the embodiment of the invention directed to a door panel303having a pet travel door301installed therein that is separated from the door100and adapted to be positioned in a space in door100where a door panel105may have otherwise been located (illustrated inFIGS.2,3and3A), the recess1510may be formed in the body member201of the door panel303. As also illustrated inFIGS.17A and17B, one or more receiving channels1512may be provided to receive the structural post members901. Within the recess1510there may be a structural member1501that is matingly engaged within the recess1510. On the structural member1501there may be one or more structural member through channels1503that may be positioned to align with the receiving channels1512on the recess1510. As illustrated inFIG.18A, the U-shaped structural member1502may be placed to overly the structural member1501and the recess1510. The U-shaped structural member1502may include one or more U-shaped structural member through channels1504(illustrated inFIG.16A) that may be positioned to align with the structural member through channels1503and the receiving channels1512. Now referring back toFIGS.15B and17B, at an upper portion of the passageway304that is in either the body member201or the door panel105, there may be a recess1510that accepts the mating placement of a structural member1501. Referring toFIG.16B, the structural member1501may include a lock slot1601that may be configured to accept the engagement of the locking arm601when the lock member104is engaged. There U-shaped structural member1502may also include a structural member lock slot1505that may be configured to align with the structural member lock slot1601on the structural member1501that is placed in the recess1510at the upper portion of the passageway304of either the body member201or a door panel105. The U-shaped structural member1502may be positioned to matingly engage and overly the structural member1501, as illustratively shown inFIGS.16B and18B. The U-shaped structural member lock slot1505and the structural member lock slot1601may be positioned to align with one another. Now referencingFIGS.22A and22B, an embodiment of the present invention may not include a structural member1501and may only include a U-shaped structural member1502that may be adapted to be matingly placed to overly a lower portion or an upper portion of the body member201. If only a U-shaped structural member1502is used, those skilled in the art will notice and appreciate that the U-shaped structural member's1502aforementioned features apply just the same even without any structural members1501or recesses1510while still accomplishing all the goals, features, and advantages of the present invention. Now referring toFIG.16B, the structural member lock slot1601is shown being formed through the structural member1501. The structural member1501is preferably adapted to be positioned on the upper portion of the passageway so that the structural member lock slot1601is aligned with a lock slot formed in the body member201. The alignment of the structural member lock slot1601with the lock slot formed in the body member201advantageously allows for rotatable movement of the locking arm601between the locked position where the locking arm is engaged with the U-shaped structural member lock slot1505, the structural member lock slot1601and the lock slot formed through the body member201, and the unlocked position where the locking arm601is disengaged from the U-shaped structural member lock slot1505, the structural member lock slot1601and the lock slot formed through the body member201. Now referring back toFIG.1A, the door panel105in a main body member101may have a door panel receiving slot that may be configured to allow for the mating engagement of the locking arm601when the lock member104is rotatably engaged or disengaged. The door panel105includes a similar configuration for the U-shaped structural member1502, the recess1501, the lock slots1505and1601, and the through channels1503and1504. Now referring back toFIGS.7,10,12, and16B, the pet travel door frame lock slot1203, the structural member lock slot1601, the U-shaped structural member lock slot1505, the upper security panel lock slot1104, the upper security panel structural member lock slot1002, the security panel body member lock slot701, and/or a door panel lock slot (not shown) or body member lock slot (not shown) may be positioned to align with one another to allow for movement and engagement and disengagement of the locking arm601of the lock member104. Now referring additionally toFIG.2, the locked position of the lock member104is defined by the locking arm601of the lock member104being positioned to engage the pet travel door frame lock slot1203, the structural member lock slot1601, the U-shaped structural member lock slot1505, the upper security panel lock slot1104, the upper security panel structural member lock slot1002, the security panel body member lock slot701, and/or the door panel lock slot (not shown) or body member lock slot (not shown). The unlocked position of the lock member104is defined by the locking arm601being positioned to disengage the pet travel door frame lock slot1203, the structural member lock slot1601, the U-shaped structural member lock slot1505, the upper security panel lock slot1104, the upper security panel structural member lock slot1002, the security panel body member lock slot701and/or the door panel lock slot (not shown) or body member lock slot (not shown). The pet travel door frame lock slot1203, the structural member lock slot1601, the U-shaped structural member lock slot1505, the upper security panel lock slot1104, the upper security panel structural member lock slot1002, the security panel body member lock slot701, and/or a door panel lock slot (not shown) or body member lock slot (not shown) may be configured to be at an angle such that when the locking arm601of the lock member104is rotatably moved to the locked position the locking arm601may encounter increased resistance as it is increasingly rotatably is turned, and may experience a greater amount of friction as the locking arm601is rotatably moved to the locked position. The angle referred to above is an angle that is off-center from an imaginary vertical plane traveling between ends of the lock slots1505and1601. In other words, the locking arm601may be configured so that when it is rotated into the locked position, the locking arm601is off-center from the imaginary plane to increase resistance and provide for a stronger locked position. Now referring back toFIGS.1A,1B,9,11,12,15A, and17B, the main body member or body receiving channels1512, the pet travel door frame through channels1202, the seal member through channels1103, and/or the U-shaped structural member through channels1504may be positioned to align with one another and the structural post members901and allow for the structural post members901to be matingly positioned within them when the security panel502is placed to cover the pet travel door301. Now referring additionally toFIG.10, the structural post member901on the lower security panel structural member1003may be configured to comprise of an elongated flat pate and/or cylindrical poles. The main body member or body receiving channels1512, the pet travel door frame through channels1202, the seal member through channels1103, and/or the U-shaped structural member through channels1504may be configured to comprise of a channel to accept an elongated flat plate that is used as the structural post members901, and/or the structural post members601as illustratively shown inFIG.10as cylindrical poles. Referring now additionally toFIG.19, the present invention includes a kit1900to retrofit an existing door100to include a pet travel door301. The kit1900may include a container1902, a pet travel door301carried by the container1902, and a structural member1501carried by the container1902. The kit1900may also include a U-shaped structural member1502carried by the container1902and at least one of an adhesive1904, an adhesive double-sided tape1906, at least one screw1908, and at least one bolt1910carried by the container1902. The pet travel door301is adapted to be affixed within a passageway304formed through a portion of the existing door100. The pet travel door301is also adapted to be affixed within the passageway304using at least one of the adhesive1904, the adhesive double-sided tape1906, the at least one bolt1910, and the at least one screw1908. As discussed in greater detail above, the structural member1501and the U-shaped structural member1502may have at least one through channel formed through a portion thereof. The at least one through channel may be adapted to be align with a through channel formed in the existing door100adjacent to at least one of the top and the bottom of the passageway304. The kit1900may also include a security panel502carried by the container. The security panel502may be configured to engage with portions of the pet travel door301. The security panel502may include a security panel body member102having a front face and a back face and a lower security panel structural member1003connected to a bottom portion of the security panel body member102and having a pair of structural post members901extending outwardly therefrom. The security panel502may also include a lock member104carried by a top portion of the security panel body member102. As described in greater detail above, the lock member104is rotatably moveable between a locked position and an unlocked position. The security panel502may also include an upper security panel structural member1001affixed to a top of the security panel body member102. The upper security panel structural member1001has an upper security panel lock slot1002formed therein and positioned to align with the lock slot formed in the existing door100. The kit1900may further include a seal member501carried by the container1902. The seal member501is adapted to be positioned adjacent an outer peripheral portion of the security panel body member102. The seal member501may also have a lock slot1104formed therein and positioned to align with the lock slot formed in the existing door100. Now referring toFIGS.23A-24, an embodiment of the present invention may include the security panel502being hingedly attached to an inside facing portion of the pet travel door frame302by a hinge member1702, defined as a hinged pet travel door system1700. In the system1700, the hinge member1702may be positioned on a right-hand side of the security panel502, the pet travel door301, and/or the pet travel door frame302. Those skilled in the art will notice and appreciate that the hinge member1702may be positioned in a number of locations on the security panel502, the pet travel door301, and the pet travel door frame302while still accomplishing all the goals, features, and advantages of an embodiment of the present invention such as, for example, the left-hand side of the security panel502, the pet travel door301, and/or the pet travel door frame302. The hinged member1702may be attached to the security panel502and the pet travel door frame302via rivets, screws, bolts, nails, adhesive, and/or cement. For example, rivet members1703are illustratively shown inFIG.23Cfixedly attaching the hinge member1702to the security panel502and to the pet travel door frame302. In the system1700, the security panel502may be configured to be rotatably moved between an opened position and/or a closed position by use of the hinge member1702. The opened position of the security panel502may be defined as when the security panel502is rotatably moved so that it is not covering the pet travel door301, and the closed position of the security panel502may be defined as when the security panel is rotatably moved so that it is covering the pet travel door301. The system1700may include the pet travel door lock slot1203being positioned on an inner facing side of the pet travel door frame302that is opposite of the hinge member1702, as illustratively shown inFIG.23B. The system1700may further include an alternate seal member501′ that may be attached on a perimeter of the security panel502. The security panel502may further include the lock member104being positioned on a portion of the security panel502that is on an opposing side from where the hinge member1702is attached to the security panel502. The lock member104may be configured to have the same features and functionality as mentioned above and further below herein when used with a hingedly connected security panel502. The seal member lock slot701may be positioned on the alternate seal member501′ on the same side of the security panel502as where the lock member104is positioned on the security panel502such that the seal member lock slot701is positioned to allow for the rotatable movement of the lock member104and the locking arm601. Now referring specifically toFIG.24, the system1700configuration may also include a second alternate seal member501″ that may be attached to an inside facing side of the security panel502. The second alternate seal member501″ may also be positioned on the security panel502such that the second alternate seal member501″ is overlaying the reinforcement member602. The second alternate seal member501″ may be positioned on the security panel502so that it may be about the same as the perimeter of the security panel502and may comprise of rubbers, plastics, composites, and/or elastics either in whole or in part, and either in a homogeneous or heterogenous combination. The second alternate seal member501″ may be configured to create a seal against the pet travel door301and/or pet travel door frame302when the security panel502is in the closed position as illustratively shown inFIG.23A. Alternative embodiments of the present invention may include a system2500having a door100or door panel201including an integrated pet travel door301comprising a flap2608, as illustratively shown inFIGS.1A-4and25-26. The door100may include a main body member101having lower door panel105that may have a front face a back face. A passageway304may be formed through the lower door panel105. The passageway304may be defined as having a top, a bottom, and side portioned extending between the top and bottom of the passageway304. The integrated pet travel door301may include a pet travel door frame302that may be attached to the top, bottom, and side portions of the passageway304. The integrated pet travel door301may also include a pet travel door seal2602, a bumper seal2604, a flap2608, a pair of opposing flap reinforcement members2606, and a security panel502. The pet travel door seal2602may be positioned and/or attached to the pet travel door frame302. The pet travel door seal2602may be positioned on an inward perimeter of the pet travel door frame302. The bumper seal2604may be positioned on and/or connected to the pet travel door seal2602. The bumper seal2604may be positioned extending outwardly from the pet travel door seal2602, which may me such that the bumper seal2604extends outwardly less than, further than, or the similarly as the pet travel door frame302. The flap2608may be connected to a portion of the pet travel door frame302, which may be an upper portion of the pet travel door frame302. The flap2608may be sized to fit within the interior perimeter of the pet travel door302, which may be such a sized to allow for the flap2608to not be constrained from moving with respect to the pet travel door frame302. The flap2608and the pet travel door frame302may be configured to allow for the flap2608to pivotally move with respect to the pet travel door frame302. The flap reinforcement members2606may be connected to side portions of the flap2608. The flap reinforcement members2606may extend the length of the sides of the flap2608, and may extend less than the length of the sides of the flap2608. The security panel502may be attached to a side portion of the pet travel door frame302. The security panel502may be hingedly connected to the pet travel door frame302. The security panel502may be sized to substantially cover an internal perimeter of the pet travel door frame302. The security panel502may also be size to substantially cover the flap2608. The security panel502may be moveable between a closed position and an opened position. The closed position of the security panel502may be defined as the security panel substantially contained within the internal perimeter of the pet travel door frame302, which may be so that the flap2608and/or the passageway304may be covered by the security panel502. The opened position of the security panel502may be defined as the security panel502being positioned so that the passageway304is at least partially exposed, and/or when the flap2608is at least partially exposed. The flap2608may be moveable between a closed position and an opened position. the closed position of the flap2608may be defined as when a bottom portion of the flap2608is substantially aligned with a bottom portion of the pet travel door frame302. The opened position of the flap2608may be defined as when the bottom portion of the flap2608is at least partially spaced apart from the bottom portion of the pet travel door frame302. When the security panel502is in the closed position, the flap2608may not be moveable. An upper portion of the flap2608may be pivotably attached to the pet travel door frame302, structural member1501, U-shaped structural member1502, and the door panel105, the main body member101, and/or the body member201via a swing rod extending along an upper portion of the passageway304. The flap2608may also include one or more magnets positioned at a lower portion of the flap2608that may be used to pull and/or hold the flap2608in the closed position by the one or more magnets coming into proximity with other positioned adjacent to a lower portion of the passageway304. The pet travel door seal2606and/or the flap2608may be configured so that the pet travel door seal2606abuts an outer perimeter of the flap2608when the flap2608is in the closed position. When the pet travel door seal2606is abutting the flap2608there may be a restriction of air or objects from passing through and/or around the flap2608. The pet travel door seal2606may include one or more of felt weather stripping, reinforced those weather stripping, metal weather stripping, plastic weather stripping, foam tape weather stripping, closed cell foam weather stripping, rubber weather stripping, brush pile weather stripping, gray pile weather stripping, and wool pile weather stripping. Preferably, the pet travel door seal2606comprises of wool pile weather stripping. The security panel502and/or the bumper seal2604may be configured such that when the security panel502is in the closed position, the bumper seal2604abuts against the security panel502. When the bumper seal2604abuts against the security panel502, there may be a restriction of air or objects from passing through and/or around the security panel502and/or the flap2608. The bumper seal2604may comprise of V-strip weather stripping. As is well understood by those skilled in the art, V-strip weather stripping, also known as a “tension seal,” is a strip of material that is folded to have an elongated “V” shape. The V-strip weather seal may have a flexibility allowing the “V” shape to fold along the elongated “V” shape when a force is applied perpendicular to the V-strip weather stripping. The V-strip weather stripping may also have a shape memory such that when no perpendicular force is applied to the V-strip weather stripping, the V-strip weather stripping readily returns to the elongated “V” shape. When a surface is in contact with, and applies a pressure towards the V-strip weather stripping, the V-strip weather stripping may also apply a force towards the surface to further increase the seal made by the surface against the V-strip weather stripping. Now additionally referring toFIGS.5-10, the security panel502may include a lock member104that may be carried by a side portion of the security panel502. The lock member104may include a locking arm601. The lock member104may be configured to be rotatably moveable between a locked position and an unlocked position. The locked position of the lock member104may be defined by a locking arm601of the lock member104being positioned to engage a lock slot1203formed in a portion of the lower door panel105that may be adjacent one of the side portions of the passageway304. The unlocked position of the lock member104may be defined as the locking arm601being positioned to disengage the lock slot1203. The lock member104may be configured to increase the pressure of the abutment of the security panel502against the bumper seal2604when the lock member is in the locked position. Specifically, the lock slot1203may be angled so that when the locking arm601of the lock member104is moved to the locked position, the locking arm601has a force exerted on it at an inwardly direction. As mentioned further above, the lock member104may include a key lock801. The key lock801may be used to restrict the movement of the lock member104when the key lock801is in the locked position, and the lock member104may be free to rotatably move when the key lock801is in the unlocked position. Specifically, the key lock801may be moveable between an unlocked position and a locked position. When the key lock801is in the locked position the lock member104may not be moveable between the locked position and the unlocked position, and when the key lock801is in the unlocked position the lock member104may not be moveable between the locked position and the unlocked position. Continuing to refer toFIGS.5-10and25-26, the security panel502may also include one or more post members901that may be positioned and/or attached to/on an outward perimeter of the security panel502. The post members901may be configured to matingly engage with a respective number of receiving channels1202,1503,1504,1512formed within/through the pet travel door frame302, structural member1501, U-shaped structural member1502, and the door panel105, the main body member101, and/or the body member201when the security panel502is in the closed position. Now referring toFIG.19, an embodiment of the present invention may be directed to a kit1900used to retrofit an existing door to include a pet travel door system2500. The kit1900may include a container1902, such as a box, package, or crate, that may be used to carry various members and components of an embodiment of the present invention. For example, without limitation, the container1902may carry a pet travel door system2500that may include a pet travel door frame302, a pet travel door seal2602, a bumper seal2604, a flap2608, a pair of flap reinforcement members2606, and a security panel502. The kit1900may also include adhesive and/or adhesive double-sided tape. Now referring toFIG.27, an embodiment of the present invention may include one or more hinge members1702that comprise detachable hinges. The detachable hinges may include lift off hinges, slip off hinges, leaf and pin hinges, flag hinges, weld-on bullet hinges, flag hinges, block hinges, barrel hinges, and any other detachable/removable hinges as understood by those skilled in the art. The detachable hinges may be configured to have two portions that may matingly engage one another to act as a hinge that may rotatably move about an axis. The detachable hinges may be configured to have the two portions of the detachable hinge to disengage one another so that the two portions of the detachable hinge are separated and not matingly engaging one another. For example, when detachable hinges comprising lift off hinges are used as the hinge member(s)1702to hingedly attach a security panel502to the pet travel door frame302, a user may lift upwards on the security panel502to have the two portions of the hinge member(s)1702disengage one another so that the security panel502may be removed from its attachment to the pet travel door frame302. All of the above mentioned and unmentioned, members, components, and pieces of the embodiments of the present invention may be connected, affixed, and/or attached by one or more of bolts, nuts, screws, nails, adhesive, adhesive tape, adhesive double sided tape, cement, epoxy, glue, grout, tar, welding, and/or any other way of connecting/affixing/attaching the members and components of the present invention as understood by those skilled in the art. Those skilled in the art will notice and appreciate that the members and components of the present invention may be attached in a number of ways and still accomplish all the goals, features, and advantages of the present invention. Preferably, in the embodiments of the present invention any fasteners used to attach, affix, and/or connect the pieces, members, and/or components of the present invention such as, without limitation, nuts, bolts, screws, and/or nails are only accessible from an inside facing side of the present invention. Embodiments of the present invention may also be adapted to be installed into walls, windows, glass doors, panels, and other surfaces rather than in a door100as described herein while still accomplishing all the goals, features, and advantages of the present invention. Some of the illustrative aspects of the present invention may be advantageous in solving the problems herein described and other problems not discussed which are discoverable by a skilled artisan. While the above description contains much specificity, these should not be construed as limitations on the scope of any embodiment, but as exemplifications of the presented embodiments thereof. Many other ramifications and variations are possible within the teachings of the various embodiments. While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made, and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best or only mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. Thus the scope of the invention should be determined by the appended claims and their legal equivalents, and not by the examples given. | 49,353 |
11859443 | DESCRIPTION As shown inFIG.1, a gated barrier is indicated by the reference number10. Gated barrier10includes a barrier frame12, a gate14, a latch apparatus16, and a latch receiver18. The barrier frame12is one-piece and integral and includes a first upright standard20, a second standard22and a horizontally extending lowermost threshold frame member24. The standards20,22and threshold24form an upright U-shape so as to include an open top. Standards20,22, and threshold24are tubular and formed of metal such as steel or aluminum. Standards20,22and threshold24are rectangular in section. Standard20is offset from one end of threshold24. Standard22is offset from the other end of threshold24. Barrier frame12includes an outwardly extending horizontal upper frame member26that extends in a one-piece and integral fashion outwardly from the top of standard20. Barrier frame12includes an outwardly extending horizontal upper frame member28that extends in a one-piece and integral fashion outwardly from the top of standard22. Upper frame members26,28are square in section and tubular and formed of metal such as steel or aluminum. Barrier frame12includes a vertically extending frame member30extending to and between the upper frame member26and the threshold24. Vertical frame member30runs parallel to standard20. Vertical frame member30is one-piece and integral with upper frame member26and threshold24. Vertical frame member30is oblong shaped in section from the upper frame member26to the threshold24. Vertical frame member30is tubular and formed of metal, such as steel or aluminum. Vertical frame member30is spaced inwardly from the outer end of upper frame member26and its respective outer end of the threshold24. Vertical frame member30is adjacent to and spaced apart from standard20. Vertical frame member30is set outwardly of standard20. Barrier frame12includes a vertically extending frame member32extending to and between the upper frame member28and the threshold24. Vertical frame member32runs parallel to standard22. Vertical frame member32is one-piece and integral with upper frame member28and threshold24. Vertical frame member32is oblong shaped in section from the upper frame member28to the threshold24. Vertical frame member32is tubular and formed of metal, such as steel or aluminum. Vertical frame member32is spaced inwardly from the outer end of upper frame member28and its respective outer end of the threshold24. Vertical frame member32is adjacent to and spaced apart from standard22. Vertical frame member32is set outwardly of standard22. Barrier frame12includes an upper inwardly extending piece34that is one-piece with the barrier frame12and is formed of plastic. Piece34includes a receiver formed therein for receiving an upper and inner corner of standard20. The receiver extends upwardly from a bottom of the piece34and inwardly from an outer side of the piece34. The receiver is internal of piece34. Barrier frame12includes the latch receiver18. Latch receiver18is an upper inwardly extending piece that is one-piece with the barrier frame12and is formed of plastic. Latch receiver18includes a receiver formed therein for receiving an upper and inner corner of standard22. The receiver extends upwardly from a bottom of the latch receiver18and inwardly from an outer side of the latch receiver18. The receiver is internal of the latch receiver18. Gated barrier10is a pressure gate. That is, at the factory the barrier frame12is manufactured so as to naturally space the latch receiver18from the latch apparatus16. One way to achieve such a result is to fabricate the inside angle between the threshold24and the standard22to be obtuse. Obtuse means greater than a ninety degree angle. Another way to achieve such a result is to fabricate the inside angle between the threshold24and standard20to be obtuse. Another way to achieve such a result is to fabricate the barrier frame12such that both such inside angles are obtuse. Such inside angles are the angles between the inner edges of the standards20,22and the upper edge of the threshold24. At the time up set up, the end user operates the hand wheel apparatus36,38,40,42to fix the gated barrier10between two opposing vertical surfaces. Namely, the end user operates hand wheel apparatus40to push the latch receiver18into an operating relationship with the latch apparatus16. A proper operating state of the gated barrier10is where, for example, the axis of standard20is drawn or pushed to become parallel with the axis of standard22or where, for example, the axis of standard22is drawn or pushed into a right angle with the axis of threshold24or where, for example, the axis of standard20is drawn or pushed into a right angle relationship with the axis of threshold24or where, for example, the axis of standard20and the axis of standard22is drawn or pushed into a right angle relationship with the axis of threshold24or where, for example, the latch receiver18is drawn to a proper operating position with latch apparatus16. The pressure bias of the pressure gate or gated barrier10is maintained naturally over the life of the gated barrier10such that when the hand wheels36,38,40,42are operated so as to take down the gated barrier10, the latch receiver18will naturally draw apart from the latch apparatus16. In other words, one or more of such inside angles will return to the obtuse state in which it was fabricated. Frame12may include frame extensions44and46. Each of the frame extensions44,46includes upper and lower horizontally extending frame members48,50. Upper frame member48is square in section, tubular, formed of metal such as steel or aluminum, and includes the same depth and height as upper frame member26. Lower frame member50is rectangular in section, tubular, formed of metal such as steel or aluminum, and includes the same depth and height as the threshold24. Integral and one-piece with the upper and lower frame members48,50are a pair of vertically extending frame members52,54. Each of the vertically extending frame members52,54are oblong in section from the upper frame member48to the lower frame member50, tubular, and formed of metal such as steel or aluminum. Vertical frame member52is an outer frame member. Vertical frame member54is an inner frame member. Vertical frame members52,54are adjacent to and spaced apart from each other. Vertical frame member52is spaced inwardly from the outer ends of frame members48,50. Vertical frame member54is spaced outwardly from the inner ends of frame members48,50. Inner vertical frame member54is adjacent to and spaced apart from standard20. Each of the inner ends of each of the upper and lower frame members48,50includes a rod rigidly affixed thereto and extending inwardly. The rod is inserted into an opening in a piece or plug that closes off the otherwise open outer end of the threshold24and upper frame member26or28. The opening in this piece or plug is the opening that receives a shaft of one of the hand wheel apparatus36,38,40,42. Such piece or plug may be frictionally set in such open end or may be welded to such open end. This piece or plug closes off the a) the otherwise open outer ends of the threshold24, b) the otherwise open outer end of the upper horizontal frame member26, c) the otherwise open outer end of upper horizontal frame member28, d) the otherwise open inner ends of upper frame members48, e) the otherwise open inner ends of the lower frame members50, f) the otherwise open outer ends of the upper frame members48, and g) the otherwise open outer ends of the lower frame members50. All pieces plugs include a circular opening. In the pieces or plugs found on the inner ends of upper and lower frame members48,50, the above mentioned rod that is rigidly affixed to such inner ends extends through the circular opening found in such pieces or plugs. Such rod then extends through the circular opening in the adjacent piece or plug found 1) on the outer ends of the threshold24, 2) the outer end of upper frame member26, and 3) the outer end of upper frame member28. The gated barrier10includes the hand wheel apparatus36,38,40,42. Each of the hand wheel apparatus36,38,40,42includes a threaded shaft57, a two part pressurized hand wheel58turnable on and threadingly engaged to the threaded shaft57, and a disk60fixedly engaged to the outer end of the threaded shaft57. The threaded shaft57slidingly engages the circular opening in the piece or plug in the outer ends of members48,50without threadingly engaging such circular opening. The two part pressurized hand wheel58includes an inner face that brings pressure to bear on the piece or plug or on any outer end of 1) upper frame member26, 2) upper frame member28, 3) any of the upper frame members48, 4) the threshold24, and 5) any of the lower frame members50. The disk60may be received in a receptacle shaped wall cup (not shown) that is anchored to a vertical surface by, for example, a pin connector. When the two part pressurized hand wheel58is turned so as to travel axially inwardly, the two part pressurized hand wheel58lengthens the effective distance of the threaded shaft57between the vertical surface61and the gated barrier10, thereby pressurizing the gated barrier10and pushing in the latch receiver18to the latch apparatus16. Gate14includes a gate frame66. Gate frame66includes a vertically extending end frame member68that defines the swing or pivot axis of the gate14. Vertical frame member68is pivotally engaged between piece34and the upper face of threshold24. Vertical frame member68is tubular, square in section, and formed of a metal such as steel or aluminum. A pin engages the upper end of vertical frame member68to piece34and another pin engages the lower end of vertical frame member68to the threshold24. Opposite of vertical end frame member68, gate frame66includes a vertically extending end frame member70that is tubular, square in section, and formed of a metal such as steel or aluminum. Vertical end frame members68,70are engaged to each other by an uppermost frame member72and a lowermost frame member74. Frame members72,74are tubular, square in section, and formed of metal such as steel or aluminum. Uppermost frame member72extends from an upper portion of vertical frame member68, through the latch apparatus16, to an upper portion of vertical end frame member70. Lowermost frame member74extends from a lower portion of vertical frame member68to an L-shaped piece75that is fixed to and between ends of lowermost frame member74and vertical frame member70. Gate frame66includes a pair of internal vertical support members76that are equal in height. Gate frame66includes a pair of internal vertical support members78that are equal in height and have a longer length than internal vertical support members76. Gate frame66includes a single internal vertical support member80that is longer length than internal vertical support members76and78. Each of the internal vertical support members76,78,80is oblong in section, tubular, and formed of a metal such as steel or aluminum. Each of the internal vertical support members76,78,80is engaged to and between the uppermost frame member72and the lowermost frame member74. Vertical support members68,70,76,78,80are adjacent to and spaced apart from at least one other vertical support member68,70,76,78,80. End vertical support members68,70are adjacent to and spaced apart from standards20,22, respectively. Gate14includes a pair of turn up and turn down arms82that are pivotally affixed to the L-shaped piece75. The arms82may be independent of each other, such that arms82may be turned up and down independently of the other arm82. The arms82may be fixed to each other such that turning one arm82necessarily turns the other arm82. The arms82engage opposing faces of the threshold24to prevent swinging of the gate14both ways or one way. As shown inFIG.2, two part pressurized hand wheel58, or visual indicator58, includes a base portion100having a threaded nut102, a slide portion104, and a coil spring106. Base portion100is receptacle shaped and includes a disk shaped rear wall108having an opening110formed therein for receiving and engaging the threaded nut102. An endless cylindrical sidewall112projects forwardly of the rear wall108from a peripheral edge of the rear wall108. Sidewall112is L-shaped so as to form an inwardly extending and endless ledge114. Endless ledge114defines an inner circular opening116that leads into an interior118of base portion100. Nut102is engaged in opening110and includes an opening120therein that receives shaft57. Each of shaft57and opening120are threaded. Shaft57and nut102threadingly mate with each other such that when base portion100is rotated, base portion100travels axially along shaft57. When base portion100is rotated one way, base portion100travels axially in a first direction. When base portion100is rotated the other way, base portion100travels axially in a second and opposite direction. Nut and base portion100are one-piece. Slide portion104is receptacle shaped and includes a disk shaped front wall122having an opening124therein for receiving and floating on shaft57. Opening124preferably does not threadingly engage shaft57. Opening124has a diameter slightly greater than the outermost diameter of threaded shaft57. An endless cylindrical sidewall126projects rearwardly of the front wall122from a peripheral edge of the front wall122. Sidewall126is L-shaped so as to form an outwardly extending and endless ledge128. Front wall122and sidewall126define a cylindrical shaped and receptacle shaped interior130of the slide portion104. The outwardly extending ledge128of the slide portion104engages the inwardly extending ledge114of the base portion100so as to engage the slide portion104to the base portion104. Coil spring106at all times pushes the base portion100and slide portion104apart from each other. Coil spring106is compressed at all times in the two part pressurized hand wheel58. Coil spring106includes a first end portion132that engages the front face of the rear wall108of the base portion100. Coil spring106includes a second end portion134that engages the rear face of the front wall122of the slide portion104. As base portion100and slide portion104are squeezed together, the pressure exerted by coil spring106increases. To assemble the two part pressurized hand wheel58, the base part100is first engaged on shaft57at the front end136of the shaft57. Then the base part100is rotated so as to travel axially to a position adjacent to the disk60that engages the vertical surface61. Then the coil spring106is slid onto the shaft57and into the interior118of the base portion100. Then the slide portion104is slid onto the shaft57and snapped into the base portion100such that the ledges114,128engage each other. As the slide portion104is snapped into the base portion100, the coil spring106is compressed between the base portion100and slide portion104. Then the shaft57may be inserted into the end of frame member48or into the plug or piece engaged in the end of frame member48. As shown inFIG.3A, hand wheel58and frame member48are spaced apart from each other. As shown inFIG.3B, hand wheel58and frame member48are spaced apart from each other. However, hand wheel58has been rotated so as to travel axially closer to frame member48. Ledges114,128frictionally engage each other such that a manipulation of slide104causes base portion100to rotate and such that a manipulation of base portion100causes slide portion104to rotate. As shown inFIG.3C, the hand wheel58has been further rotated so as to travel further axially such that the front wall122of the slide portion104has engaged the end of the frame member48. As shown inFIG.3D, the user manipulates base portion100to rotate base portion100forwardly while the slide portion104frictionally engages the end of the frame member48such that the slide ledge128disengages from the base ledge114such that the base ledge114begins to slide on the outer face of the slide sidewall126. At the same time, the two part pressurized hand wheel58pushes in the frame member48, which in turn pushes in frame member28, which in turn draws the standard22closer to a vertical orientation and draws the latch receiver18closer to the latch apparatus16. As shown inFIG.3E, the user continues to manipulate base portion100to rotate base portion100further forwardly while the slide portion104continues to frictionally engage the end of the frame member48such that the base ledge114, already disengaged from the slide ledge128, continues to slide on the outer face of the slide sidewall126. At the same time, the two part pressurized hand wheel58pushes in the frame member48, which in turn pushes in frame member28, which in turn draws in standard22to a position where the standard22is at a general right angle to threshold frame member24and where the latch16has engaged the latch receiver18such that the gated barrier10, barrier frame12, and gate14are in an operating position where the gate14is operable. As shown inFIG.4, the entire cylindrical exterior of the cylindrical sidewall126of the slide portion104is of a first color, except for narrow cylindrical front band designated G that confronts the front wall122of the slide portion104. In other words, cylindrical sidewall126has two cylindrical bands of color designated G (for green) and R (for red) where cylindrical band G confronts front wall122and extends rearwardly to cylindrical line138, and where cylindrical band R extends rearwardly from cylindrical line138to ledge128. When the two part pressurized hand wheel58is rotated through the positions shown inFIGS.3A,3B,3C,3D, and3E, red band R slowly begins to be covered by the cylindrical sidewall112and ledge114of base portion100and thereby slowly disappears. When the ledge114arrives at cylindrical line138, then latch16is properly aligned with the latch receiver18and the gated barrier10is in its proper operating position. It should be noted that the strength or compressive power or pressure of coil spring106is selected based upon the pressure required by the gate barrier10to draw the latch16to the latch receiver18such that the latch16and latch receiver18operate properly. The exterior sidewall112and ledge114of the base portion100are of a color different from green and different from red. The present visual indicator58or two part pressurized hand wheel58may be used only at corner location40on the gated pressurized barrier and conventional hand wheels may be used at the other three locations36,38, and42. However, if desired, the two part pressurized hand wheel58may be used at all four corner locations36,38,40, and42. Thus since the invention disclosed herein may be embodied in other specific forms without departing from the spirit or general characteristics thereof, some of which forms have been indicated, the embodiments described herein are to be considered in all respects illustrative and not restrictive. The scope of the invention is to be indicated by the appended claims, rather than by the foregoing description, and all changes which come within the meaning and range of equivalents of the claims are intended to be embraced therein. | 19,190 |
11859444 | DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S) Built-in retractable screens are becoming increasingly popular in both residential and commercial buildings. Installation of retractable screens preferably is done during the original construction and requires coordination between the builder and the screen installer. Once a specific screen product is selected, the dimensions required for the screen and header assembly is provided by the screen installer to the builder. Then, the builder constructs the frame and attempts to install the masonry or woodwork leaving cavities of the specified dimensions for later installation of the screen components. This allows opportunity for error in the communication of the dimensions as well as adherence of the dimensions by the various workmen who install the masonry or woodwork wall surfaces. The present invention provides a custom cavity system that simplifies the installation process and reduces the likelihood of errors during the construction of the framework and wall surfaces. Turning now to the drawings in general and toFIGS.1and2in particular, there is shown therein a building structure, designated generally by the reference number10. The wall12of the building10has several multiple large arched openings, one of which is designated at14. These arched opening connect an inside space16, such as a lanai, with an outside space18, such as a patio, as shown inFIG.1.FIG.1illustrates the built-in retractable screens20installed and partially lowered. As explained above, when the wall surfaces are applied to the frame, a screen cavity of specified dimensions is provided inside the wall12to receive the retractable screen unit20. As shown inFIG.2, an access opening22is left, usually in the interior wall surface, to install the screen unit20(FIG.1) in the screen cavity and thereafter to access the screen unit for maintenance and repair. The header assembly and method of the present invention is designed for use with conventional screen units.FIG.3illustrates a typical screen unit20installed in a header assembly made in accordance with the present invention. As both ends of the screen unit20are similar, only one end is shown and described here. The screen unit20generally comprises a retractable screen panel30deployable from a roll32inside an elongate magazine or housing34. The roll32has first and second ends. Only the first end36is shown in the fragmented view ofFIG.3. The screen panel30has first and second side edges. Only the first side edge38is shown. The bottom of the screen panel30terminates in a leading or bottom edge40, which is usually provided with a weighted slidebar42. The screen unit20includes first and second vertical side tracks46and48(see alsoFIGS.4&5). Each track46and48has a forwardmost surface46band48bthat defines a vertical slot to receive one of the first and second side edges of the screen panel when the screen unit is installed in the structure to receive. Thus, the side tracks46and48guide and stabilize the side edges38of the screen panel30as it is raised and lowered. The screen unit20may be one of an assortment of stock sizes or it may be custom made to the designer's specifications. With continuing reference toFIG.3and referring now also toFIGS.4and5, a preferred header assembly will be described. The header assembly of the present invention, designated generally by the reference number50generally comprises first and second end boxes54and56. Each end box54and56defines a five-sided recess58(FIG.4) and60(FIG.5), respectively, with a screen receiving opening62and64. As seen inFIG.3, the recess58of the end box54is sized to receive the first (or second) end36of the screen housing34through the screen receiving opening62. A top header66extends between the end boxes54and56. The header66has first and second ends68and70. Each of the first and second ends68and70is sized to be received inside the recess of the first or second end boxes54and56. Preferably, the top header66has a width about the same as the width of the end boxes and is fit inside the upper end of each end box. The bottom of each end box54and56has a forwardmost edge54aand56aand a track receiving opening72and74sized to receive the upper ends46aand48aof the first and second side tracks46and48of the screen unit20. The vertical side tracks46and48are mounted to the building's frame (not shown) with the upper ends46aand48aof the first and second side tracks46and48received in the track receiving openings72and74. With the screen housing34(FIG.3) mounted between the end boxes54and56, the leading edge40of the panel30may be inserted into the side tracks. In some installations, all or part of the header assembly50is exposed after surrounding wall surfaces have been applied. In such cases, the header assembly50may include a second bottom header76, as seen only inFIG.5. The first and second ends77and78of the bottom header76are sized to be received in the recesses58and60of the end boxes54and56, and preferably in the bottom of the end boxes adjacent the upper ends46aand48aof the side tracks46and48and spaced a distance below the upper header66. Now it will be apparent that the assembled header assembly50and screen unit side tracks46and48define a custom screen cavity80in the structure's frame about which the wall surfaces12may be installed. More specifically, the tops of the end boxes54and56and the top header66form the uppermost boundary of the screen cavity80, and the ends of the end boxes and the side tracks46and48form the sides of the cavity. With these fixed structures in place, the builder's workers can simply apply the wall finishes around them. Now it will be understood that in the assembled header assembly50the space between the first and second end boxes54and56and below the top header66(and above the bottom header76when it is included) defines the access opening22in the finished wall12, as seenFIG.2. Turning now toFIGS.6-11, a particularly preferred structure for the end boxes54and56will be explained. In the preferred embodiment of the present invention, the end boxes54and56are identical and reversible, that is, each end box is formed so that it can be used on either end of the header assembly50. Thus, only one of the end boxes, namely the end box54, will be shown and described in detail. As mentioned previously, the end box54is defined by five sides which defines an end box recess58(FIG.4) with a screen receiving opening62. The five sides include a vertical end wall90which is opposite the screen receiving opening62. Also included are a back wall92and a front wall94opposite of and parallel to the back wall. Still further, the sides include a first side wall96and a second side wall98opposite of and parallel to the first side wall. The back wall92, front wall94, and first and second side walls96and98all are perpendicular to the vertical end wall90. As used herein, “front” refers to the aspect of the assembly seen from inside the building, that is, the aspect shown inFIGS.3-5, for example. “Back,” as used herein, refers to the side of the header assembly facing toward the outside of the building, that is, the side opposite the side shown inFIGS.3-5, for example. “Vertical,” as used herein refers to plan perpendicular to the floor or supporting platform of the building structure. The first side wall96defines a first track receiving opening100sized to receive the upper end46aor48aof the first or second side tracks46or48when the end box54is positioned with the first side wall as the bottom of the recess58. Similarly, the second side wall98defines a second track receiving opening102sized to receive the upper end46aor48aof the first or second side tracks46or48when the end box54is positioned with the second side wall as the bottom of the recess58. A portion of the vertical end wall90may be removed to form an end window106. This reduces the weight of the end box. Additionally, it may simplify attachment of the electrical junction box “J” (seeFIG.4) inside the end box. A portion of the front wall94preferably is cut away to form a large notch108, as this will facilitate positioning of the screen unit housing34(FIG.3) inside the header assembly50. The end boxes may be formed of metal, such as galvanized steel. For example, a blank may be stamped or cut to have the openings as described and then folded into the five-sided shape. Still further, the end boxes may be molded of plastic or a composite material. The access opening22(FIG.2) may be provided with a removable cover. An exemplary cover is shown inFIGS.12-21to which attention now is directed. The cover, designated generally at110may comprise a front panel112and in some cases a bottom panel114supported on one or more brackets116. As shown, the cover panels112and114are simply boards or other panel material sized to be coextensive with the opening22. The bracket116may be a C-shaped bar having a front section118for attachment of the front panel112, a bottom section120for attachment of the bottom panel114, and a top section122sized to hang on the top header66, as seen best inFIG.12. The number and relative positions of the brackets116may vary. Only one is shown inFIG.12to simplify the illustration. Thus, the assembled cover110easily may be placed over and removed from the access opening22. The header assembly may be made and sold independently of the screen unit. For example, universal end boxes may be made in one or more standard sizes to fit a number of different brands of screen units. Alternately, a screen kit may be provided that includes the screen unit (screen panel, housing, and side tracks, etc.) along with end boxes made specifically for that screen unit. The upper and lower headers may or may not be included, as these are easily made on site of standard board lumber. A cover for the access opening may be included. Or, the kit may include brackets for a cover to be made of lumber on site. Having described the inventive header assembly, the method of the present invention now will be described. First, a screen unit is selected by the builder, designer or architect. Next, the dimensions of the selected screen unit are determined, and the components of the header assembly are selected and sized. After the builder has constructed the building frame and prior to the application of the surrounding wall surfaces, the screen installer will assemble and install the header assembly. This includes installing the first and second end boxes and securing the top header and, if needed, the bottom header. The side tracks form the selected screen unit are obtained and secured to the building frame so that one end of each of the side tracks opens into the track receiving opening in the bottom of one of the end boxes. Thus, the custom screen cavity is created in the building frame. After the builder has applied the wall surfaces around the custom screen cavity, the selected screen unit is installed inside the custom screen cavity. Then, if desired, a cover panel is placed over the access opening. Now it will be appreciated that the header assembly and method of the present invention greatly simplifies the installation of built-in retractable screens. In accordance with the assembly and method of the present invention, a custom header assembly and the screen unit's side tracks are installed in the wall of the structure after the builder has constructed the building frame and prior to the application of the wall surfaces. Then, the builder applies the wall surfaces, such as masonry, wood, stucco, and the like. The wall finishes are applied over and around the fixed header assembly and side tracks, leaving open only an access opening for servicing the installed screen unit. In this way, the builder and his workmen are freed of the need to build around a void by repeatedly, and sometimes inaccurately, measuring. The embodiments shown and described above are exemplary. Many details are often found in the art and, therefore, many such details are neither shown nor described herein. It is not claimed that all of the details, parts, elements, or steps described and shown were invented herein. Even though numerous characteristics and advantages of the present inventions have been described in the drawings and accompanying text, the description is illustrative only. Changes may be made in the details, especially in matters of shape, size, and arrangement of the parts within the principles of the inventions to the full extent indicated by the broad meaning of the terms of the attached claims. The description and drawings of the specific embodiments herein do not point out what an infringement of this patent would be, but rather provide an example of how to use and make the invention. Likewise, the abstract is neither intended to define the invention, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way. Rather, the limits of the invention and the bounds of the patent protection are measured by and defined in the following claims. | 13,069 |
11859445 | DETAILED DESCRIPTION The apparatus of the annexed figures shall be deemed to be schematically illustrated, not necessarily drawn to scale, and not necessarily representing the actual proportions of its parts. Although this is not expressly shown, the individual features described with reference to each embodiment shall be intended as auxiliary and/or interchangeable with other features, as described with reference to other embodiments. Referring to the accompanying figures, numeral1designates an insulating glazing unit designed for use in windows of buildings, to ensure thermal insulation of the indoor environment from the outdoor environment. Particularly referring toFIG.1, the insulated glazing unit1comprises a frame12. This frame12comprises a base13, a cross member15placed above the base13and two upright members14for connection between the cross member15and the base13. More in detail, the base13has two opposite ends131. The two upright members14are connected to the base13at the ends131of the base13. In other words, each upright member14is connected to one respective end131of the base13. Likewise, the cross member15has two opposite ends151. Each of the two ends151of the cross member15is located above one respective end131of the base13. The two upright members14are connected to the cross member15at the ends151of the cross member15. In other words, each upright member14is connected to one respective end151of the cross member15. Preferably, the base13and the cross member15are parallel and opposite to each other. As a result, the two upright members14for connection of the base13and the cross member15are also parallel and opposite to each other. The insulated glazing unit1comprises at least two at least partially transparent panes, which are applied to the frame12. The at least two panes are in mutually facing and parallel relationship. The at least two panes are preferably made of glass and are completely transparent. While two panes of glass are used in one embodiment, three or four panes of glass may be also provided. The at least two panes are applied to the frame12in air-tight fashion, for instance to contain gas, thereby defining a hermetically sealed inner volume18. The insulated glazing unit1comprises a light ray shielding device2placed in the volume18as well as drive means to drive the light ray shielding device up and/or down. In particular, the light ray shielding device2comprises a plurality of slats21and a bottom member22. The slats are connected to each other and to the bottom member22. In a preferred embodiment of the present invention, the light ray shielding device2is embodied by a venetian blind. For the purposes hereof, it should be noted, also with reference toFIG.1, that the drive means comprise support means attached to the cross member15, such as a box23. The box23receives, as is known per se, a shaft which is coupled to an electric motor and its electronics to cause movement of the light ray shielding device2(not shown). In particular, the shaft in the box23is connected to the slats21and the bottom member22by means of cords and ladders, also in a well-known manner, that will not be disclosed herein. In one aspect, the plurality of slats21, the bottom member22and the box23extend between the two upright members14of the frame12. In one aspect the bottom member22of the light ray shielding device2has two opposite ends221. In particular, such ends221are placed proximate to the upright members14of the frame12. It shall be noted that the light ray shielding device2is adapted to alternate between a raised position and a deployed position. In the raised position the slats21and the bottom member22are compacted together. In other words, in the raised position the slats21and the bottom member22are compacted together at the box23applied to the cross member15. In the deployed position the bottom member22is placed proximate to the base13of the insulated glazing unit1. In particular, in the deployed position the bottom member22is spaced apart from the box23, whereas the slats21span the space between the bottom member22and the box23. In other words, in the deployed position the slats21span substantially the entire space between the cross member15and the base13of the frame12. It shall be noted that the aforementioned drive means are adapted to alternate the light ray shielding device2between the raised position and the deployed position. It shall be noted that the light ray shielding device2may assume a series of intermediate positions between the raised position and the deployed position. In the intermediate positions, the bottom member22is located in an intermediate position between the base13and the box23. In other words, the bottom member22is spaced apart from both the base13and the box23. Furthermore, some of the slats21are compacted at the box23, whereas the rest of the slats23span the space between the bottom member22and the box23. In the deployed position and in the intermediate positions the slats21may alternate between an open configuration and a screening configuration. In the open configuration, the slats21are substantially perpendicular to the panes. In addition, the slats are spaced apart from each other and in this configuration, light is allowed to pass between the slats21. In the screening configuration the slats are in a partially overlapping relationship. The partial overlapping relationship of the slats21blocks the passage of light in the space between the bottom member22and the box23of the light ray shielding device. The bottom member22of the light ray shielding device2is configured to alternate between a first configuration and a second configuration. Particularly referring toFIG.3a, in the first configuration, the bottom member22can slide toward/away from the base13thereby defining a slide direction X. Particularly referring toFIG.3d, in the second configuration the bottom member22is proximate to the base13and is tilted with respect to the slide direction X. It shall be noted that, in the first configuration, the bottom member22can reversibly slide from the box23toward the base13of the frame12, in particular to alternate the light ray shielding device2from the raised position to the deployed position. Preferably, as the bottom member22slides, the slats21connected thereto are deployed. In the second configuration, the bottom member22is tilted with respect to the slide direction X by a predetermined angle. In other words, the bottom member22is rotated about an axis Y (FIG.4) of the bottom member22perpendicular to the slide direction X. Advantageously, as shown inFIGS.2and4, the tilt of the bottom member22with respect to the slide direction X causes the slats21to partially overlap proximate to the bottom member22in the screening configuration of the slats21. The partial overlapping relationship of the slats21blocks the passage of light. The insulated glazing unit1further comprises first stationary guide means24located at the base13of the insulated glazing unit1(FIGS.2and4). More in detail, the first guide means24are configured to be located at least at one end131of the base13of the insulated glazing unit1. More in detail, the first guide means24are fixed to the upright members14of the frame12. In particular, the first guide means24are fixed to the upright members14at the end131of the base13. The insulated glazing unit1further comprises second moving guide means25located on the bottom member22of said light ray shielding device2. More in detail, the second guide means25are located at least at one of the ends221of the bottom member22. The first24and the second guide means25are configured to contact each other when the light ray shielding device2is in the deployed position and to alternate the bottom member22from the first configuration to the second configuration. In other words, the mutual sliding movement between the first24and the second guide means25causes the bottom member22to alternate from the first configuration to the second configuration, thereby allowing the bottom member to rotate about an axis of symmetry. In a first embodiment as shown inFIGS.2,3a,3b,3cand3d, the first guide means24comprise at least one recess31and the second guide means25comprise at least one pin32fixed to the bottom member22. The pin32is configured to move relative to the base13of the insulated glazing unit1and to slide in the recess31. In other words, the recess31remains stationary, whereas the pin32slides in the recess31. More in detail, the pin32is fixed at one of the ends221of the bottom member22. Further in detail, the pin32is placed below the center of gravity of the bottom member22. Preferably, the pin32is placed at a plane of symmetry of one end221of the bottom member22at a predetermined distance from the center of gravity of the bottom member22. Particularly referring to the recess31ofFIGS.2and3a, this recess31has a profile50with a first section311tilted with respect to the slide direction X of the bottom member22. This first section311is configured to contact the pin32when the light ray shielding device2is in the deployed condition and to guide the sliding movement of such pin32in the recess31. In other words, the first section311is below the pin32during the sliding movement of the blind2. An insulated glazing unit as claimed in claim7, wherein the profile50of the recess31has a second section312substantially parallel to the slide direction X of the bottom member22and configured to lock the bottom member22in the second configuration. In other words, the first section311and the second section312are tilted relative to each other. More in detail, a connecting section313connects the first portion311and the second portion312of the profile. The connecting section313is substantially horizontal. The second section312prevents the pin32from sliding past the connecting section313. Therefore, this pin32is locked at the connecting section313. In the embodiment ofFIGS.2-3d, the sliding movement of the pin32along the first section311of the profile50of the recess31causes the bottom member22to tilt. In the embodiment ofFIGS.2,3a,3b,3cand3d, the first guide means24preferably comprise a pair of pins32and the second guide means comprise a pair of recesses31. Each pin32is located at one respective end221of the bottom member22, whereas each recess31is located at one respective end131of the base13. Therefore, each pin32is configured to slide in the corresponding recess31. In a second embodiment as shown for example inFIGS.4and5, the first guide means24comprise at least one pin42and the second guide means25comprise at least one recess41. The recess41is configured to move relative to the base13of the insulated glazing unit1and to slide around the pin42. In other words, the pin42remains stationary and the recess41slides around the pin42. More in detail, the pin42is located at a predetermined distance from the plane of symmetry of one end131of the base13. Particularly referring to the recess41as shown inFIGS.4and5, it will be appreciated that it has a profile60with a first section411tilted with respect to the slide direction X of the bottom member22. This first section411is configured to contact the pin42when the light ray shielding device2is in the deployed condition and to guide the sliding movement of the pin42in the recess41. Furthermore, the profile41has a second section412that is tilted to the slide direction X and is symmetric to the first section411of the bottom member22and a connecting section413between the first section411and the second section412. In the embodiment ofFIGS.4and5, the sliding movement of the first section411of the recess41around the pin42causes the bottom member22to tilt. The contact between the second section412and the pin42locks the bottom member22in the second configuration. Therefore, in the second configuration of the bottom member22, the pin42contacts the connecting section413and the second section412. Preferably, in the embodiment ofFIGS.4and5, the first guide means24comprise a pair of recesses41and the second guide means comprise a pair of pins42. Each recess41is located at one respective end221of the bottom member22, whereas each pin42is located at one respective end131of the base13. Therefore, each recess41is configured to slide around its respective pin42. Those skilled in the art will obviously appreciate that a number of changes and variants as described above may be made to fulfill particular requirements, without departure from the scope of the invention, as defined in the following claims. | 12,611 |
11859446 | Before explaining the disclosed embodiments of the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the particular arrangement shown, since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation. DETAILED DESCRIPTION Various embodiments of a cord tightening device are illustrated inFIGS.1-29. The cord tightening device of the present disclosure100as shown in use inFIG.1comprises a base101and gripping handle102. Attachment or fastening devices including a screw103and spring washer104may be used to semi-permanently or permanently attach the cord tightening device100to a surface105for operation. A cord106, or multiple cords, may be threaded through or into the cord tightening device100in an opening O of the base101such that the cord106may be shortened/tightened or lengthened/loosened as needed, yet hold taught in place after tightening or loosening. The cord tightening device100as shown inFIG.1, and following figures, may be made from plastics such as polycarbonate plastics, nylon, Acrylonitrile Butadiene Styrene (ABS), or other thermoplastics such as polypropylene, or thermosets. Thermoplastics become liquid, i.e. have a “glass transition” at a certain temperature, 221 degrees Fahrenheit in the case of ABS plastic. They can be heated to their melting point, cooled, and re-heated again without significant degradation. A thermoplastic is any plastic material with a low melting point that becomes molten when heated, solid when cooled, and can be re-melted or molded after cooling. The curing process is completely reversible and doing so will have little impact on the material's physical integrity. Thermoplastics are usually stored as pellets to facilitate easy melting during the injection molding process. Common examples of thermoplastics include acrylic, polyester, nylon, and PVC. In contrast, thermoset plastics. can only be heated once which occurs typically during the injection molding process. The first heating causes thermoset materials to set resulting in a chemical change that cannot be reversed. Thermosets are usually stored in liquid form in large containers. Common examples of thermosets include epoxy, silicone, and polyurethane. Methods of manufacture may include molding such as injection molding. For injection molding a mold is created and liquid material of manufacture is injected into the mold. This type of manufacture lends itself to high-volume, low-cost manufacturing. And because in this case, only two parts, the base101and gripping handle102, comprise the cord tightening device100, manufacture can be simple and inexpensive. Other means of manufacturing plastics may be employed such as rotational plastic molding, blow molding, extrusion, or thermoforming. Additionally, the base101and gripping handle102may be 3D printed. FIGS.2and3are top and bottom views of the base of the cord tightening device100, respectively. In theFIG.2top view, the base101and its interior along with the central cavity107that may be threaded to receive a screw but left as smooth surface as is shown in the design presented herein. Other attachment means such as a nail are envisioned. In theFIG.3bottom view, the base101and central cavity107. FIG.4is a top perspective view of the base101of the cord tightening device of the present disclosure. The base is generally circular in form with a protrusion108on one side and the central cavity107in the interior115being hollow. One may envision this interior115of the central cavity107could be threaded to receive a screw. The protrusion108serves to provide a smooth exit for a cord and stabilizes the base once tension is applied to the cord. The top rim109of the base101has a smaller diameter than the bottom rim110of the base101. Interior base ridges123B line a portion of the bottom interior of the base112. The interior of the base100and protrusion108are hollow and designed to receive the gripping handle. A central column113forms the walls of the central cavity107. An outer base wall114connects the upper rim109to lower rim110. The interior115between the outer base wall114and the central column113is hollow. FIGS.5,6, and7show a right, front, and back side view of the base101, respectively. As indicated above the top rim109has a slightly smaller diameter than the bottom rim110. The central column113is taller than the top rim109of the outer base wall114and viewable in each of theFIGS.5,6, and7.FIG.6further illustrates the form of the protrusion108of the base101and opening O for cord entry.FIG.8further illustrates a side view of the base101and serves to orient the viewer toFIG.9, a cross section of the base which is taken at9,FIG.8. As shown inFIG.9, the top rim109has a slightly smaller diameter than the bottom rim110. The central column113rises above the height of the top rim109and serves to form the hollow central cavity107. The interior115between the outer base wall114and the central column113is hollow. Interior base ridges123B and the bottom interior of the base112are viewable.FIG.10illustrates a bottom perspective view of the base of the disclosed cord tightening device. The upper rim109and lower rim110, outer base wall114, protrusion108, and hollow central cavity are visible in thisFIG.10view, along with the bottom exterior of the base116. FIG.11illustrates a perspective view of the cord tightening device100with base101, gripping handle102, and securing devices, screw103and spring washer104. The slight curved shape of the spring washer104is evident in this view. The spring washer is made of ‘spring steel’, a stainless steel that compresses when pressure is applied and springs back when the pressure is released. The screw tip103t, which would fit into a surface, is visible below the base101. The gripping handle102extends out from the base101and over the protrusion108and opening O. FIG.12illustrates a top perspective view of the gripping handle102. The gripping handle102has an overall spool shape and an inner central cavity121that is cylindrical in shape. The top flange117and top flange ridges118that ring an inner top cavity119. The inner top cavity119comprises at least one opening120, or at least two openings120, for a cord and the arbor or a cylindrical inner central cavity121which fits over the central column113(FIG.4) of the base. As shown further inFIGS.13-16, the handle bottom flange122comprises handle bottom ridges123H for engaging interior base ridges in the base interior as shown inFIG.9,123B. The barrel124connects the handle top117with the handle bottom flange122and is hollow comprising the arbor or inner central cavity121(FIG.12) for receiving the central column113(FIG.4) of the base. Note the inner top cavity119(FIG.12) bottom125extends below the handle top117. Connections126between the tube124and top cavity bottom125and handle bottom flange122are continuous with arced lines, having Fillet Radii rather than squared edges. These details may be design preference. FIG.17is a bottom perspective view of the gripping handle102. The at least one opening or two openings120extend from the inner central cavity119(not shown) through to the bottom of the central cavity125. The bottom handle ridges123H of the handle bottom flange122are shown. The top flange117has a larger diameter than the handle bottom flange122.FIG.18is a bottom view of the gripping handle102. The top flange117and handle bottom flange122, as well as bottom handle ridges123H are visible along with the inner central cavity121. FIG.19illustrates a top view of the gripping handle102. The at least one opening120or at least two openings120of the inner top cavity119are visible and20designates the view of the cross section shown inFIG.20. The partial circular raised ridge R provides a limit for the spring washer104and keeps it centered on the gripping handle. A cross section of the gripping handle102is shown inFIG.20. Top flange117and handle top ridges118that ring an inner top cavity119and an inner central cavity121for receiving the central column113(FIG.4) of the base. The handle bottom flange122comprises handle bottom ridges123H for engaging ridges123B in the base interior as shown inFIG.9,123B. A barrel124connects the top flange117with the handle bottom flange122and is hollow comprising the inner central cavity121for receiving the central column113(FIG.4) of the base. The highlighted area21illustrates these handle bottom ridges123B that are shown in more detail inFIG.21. As shown in the cross-section closer view,21,FIG.20, theFIG.21cross-section shows the handle bottom ridges123H which are of the same piece as the whole gripping handle102being a single molded piece with equally spaced ridges123H as shown. The purpose of these handle bottom ridges123H is to engage the interior base ridges123B (FIG.2) of the bottom interior of the base101. When the gripping handle102is turned clockwise, the handle bottom ridges123H are designed to push the gripping handle up in the base101and then as the handle bottom ridges123H bypass, the spring washer104pushes the gripping handle102back down in the base101. This action will tighten the cord. If the cord needs to be loosened, the user would pull the gripping handle102up and rotate it counterclockwise, when released the spring washer will reengage the ridges123H locking the gripping handle102rotation and controlling the cord tension. FIG.22illustrates how the screw103and spring washer104fit together with the gripping handle102and base101.FIG.23illustrates the curve of the spring washer104. The spring washer104is made from ‘spring steel’, a stainless steel that flattens with pressure and reforms shape upon withdrawal of pressure. The slight curve of the spring washer104as shown inFIG.23allows this spring nature. Tightening the screw103onto the spring washer104ensures a snug fit of the gripping handle into the base allowing the ridges123H of the gripping handle to engage those of the base123B as described above.FIGS.24-29illustrate how a cord106may be threaded through the device100for use as a cord tightening device. The cord tightening device100may be fixed to a surface105with the screw103and spring washer104. The design of the spring washer104ensures there is engagement between the bottom ridges of the gripping handle (not shown) and the ridges in the interior of the base101. A cord106, one end of which may be fixed to a window shade, for example, is threaded through the opening O in the base and through at least one of the openings120in the gripping handle102. To operate the cord tightening device the gripping handle102is turned clockwise. This action will tighten the cord. If the cord needs to be loosened, the user would pull the gripping handle102up/out and rotate it counterclockwise, when released the spring washer will reengage the ridges123H locking the gripping handle102rotation and controlling the cord tension. Although the present invention has been described with reference to the disclosed embodiments, numerous modifications and variations can be made and still the result will come within the scope of the invention. No limitation with respect to the specific embodiments disclosed herein is intended or should be inferred. Each apparatus embodiment described herein has numerous equivalents. | 11,395 |
11859447 | DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION With reference now to the drawings, embodiments of a window treatment system of the present disclosure, which is generally designated by the reference numeral10, will be described. It should be noted that these drawings have been drawn to scale and as such show the relative sizes of the window covering system10. Referring first toFIG.1, the window covering system10includes a tube12with a window covering14, such as a window shade, that is wrapped around the tube12in a conventional manner. The system10is delimited and supported by a first end bracket16and a second end bracket18between an opening, such as a window or a doorway (not shown). Optionally, the first end bracket16and the second end bracket18may be each covered by a bracket cover17. As shown inFIG.2, the window covering system10further includes a clutch assembly100, a booster assembly200and a limiter assembly300. These assemblies100,200,300are sized so that, except for components at the ends of the clutch and limiter assemblies100,300, the assemblies100,200,300can be arranged within the tube12and hidden from view. A wand20is disposed near the first end bracket16and attached to a cord22to aid in selectively moving the cord22between a retracted position and an extended position. By moving the cord22between a retracted position and an extended position, the window covering14can be selectively lowered or raised to a desired height between a fully extended position dictated by the overall length of the window covering14and a fully retracted position, which is set during installation of the window covering system10by the limiter assembly300. At any given time, the window covering14is locked at the preselected height by the booster assembly200and the window covering14does not go up or down except under the control of an operator. FIG.1shows the window covering14at three positions: HU, H0and H1. There are two ways to raise or lower the shade. For example, the window covering14can be lowered from a first position H0to a second position H1(seeFIG.1) by grabbing the wand20and pulling the wand20downward repeatedly, until the window covering14reaches the second position H1. The cord22is spring loaded (as described below). As the wand20is pulled downwardly, the wand20pulls at least a portion of the cord22out of the clutch assembly100causing the booster assembly200and tube12to rotate and allow movement of the window covering14. Simultaneously, a coil spring216arranged within the booster assembly200is tightened as well. Once a desired position of the window covering14is reached, the force on the wand20(and cord22) is released. The cord22and the wand20are pulled upwardly toward the clutch assembly100until the end of the wand20fixed to the end of the cord22contacts the clutch assembly100such that the clutch assembly100acts as a stop for the movement of the cord22and wand20. Because the cord22is relatively short, preferably the operator can pull on the wand20repeatedly until the window treatment is lowered to the desired position. Each time a downward force on the wand20is released, the booster assembly200automatically locks the tube12and shade14in place. To raise the window covering14from an extended position, the wand20can be pulled downwardly slightly and then released, causing the cord22and the clutch assembly100to release the window covering14. A main coil spring216of the booster assembly200applies a rotational force on the tube12causing the tube12to rotate and in turn raise the window covering. Damping forces are applied within the booster assembly200to ensure that the upward motion of the window dressing14is a controlled, relatively slow and linear in motion. As such, the booster assembly200performs two functions: (1) it provides a force necessary to raise the window covering14and (2) it acts as a speed governor by controlling the speed at which the window covering14rises when released from a resting state. It is noted that if no action is taken by an operator when the window covering14is being raised toward an upper limit HU, the window covering14will continue to rise until it reaches the upper limit HU as set and defined by the limiter assembly300. Alternatively, instead of using the wand20, an operator can grab a lower end14A of the window dressing14and manually pull the window covering14from the first position H0to the second position H1. When the window covering14is manually raised and/or lowered by pulling directly on the window dressing14, the cord22is disassociated from the booster assembly200by the clutch assembly100and remains in place together with the wand20, as explained below. To manually raise the window covering14, an operator can pull downwardly slightly and then release the lower end14A of the window covering14, causing the booster assembly200to be unlocked and thereby allowing the booster assembly200to cause rotation of the tube12, and in turn, raise the window covering14toward the upper position HU. As shown inFIG.3, the clutch assembly100includes: the first end bracket16and the bracket cover17; a self-locking ring101; a cord guard102with a boss104; a washer105; a concentric power spring106; a pulley108; an eyelet108A; a cord guard cover110; a clutch sleeve112; a cam drive dog114; a clutch spring116; a clutch spring bushing118; a compression spring120; a compression spring retainer122; a crown124; a clutch cover126; two clutch springs128; an adjusting shaft130; a clutch inner member132; a self-locking ring134; and a connector drive136. Optionally, the clutch assembly100may also include a blanking plug108B. A similar clutch is described in more detail in International Application No. PCT/AU2016/00053, the contents of which are incorporated herein by reference, with the difference being that the embodiment of the present clutch is adapted for use with a cord and wand rather than a looped cord as described in International Application No. PCT/AU2016/000053. FIGS.4-12show details of the components comprising a clutch assembly100and how these components interact with each other to provide the described functions. As can be seen inFIG.14, in an assembled state, the clutch assembly100is compact, requiring little space. The pulley108and guard102form a first cavity102X (SeeFIG.13) therebetween in order to house cord22(when it is wound) and a second cavity102Y for holding power spring106. As also shown inFIG.11A, guard102has an opening108X in which an eyelet108A (shown inFIG.9) can be arranged through which the cord22can extend in order to prolong the life of the cord22by preventing the cord22from being damaged (e.g., frayed, cut, etc.). In an embodiment, the eyelet108A is made of a long-lasting, low friction material such as ceramic or a similar material. As described below, the cord22is reciprocated up and down through the eyelet108A and may be frequently at an angle such that the cord22rubs against an inner surface of the eyelet108A. The eyelet is made of a low-friction material to prolong the life of the cord.FIG.11illustrates an embodiment with a single eyelet108A.FIGS.40A-Bshow another embodiment with eyelets108A disposed in respective holes404,406. This embodiment is described in more detail below. As discussed above, the system100can be configured for right-handed or left-handed operation. Details of the pulley108are shown inFIGS.6-7. As can be seen, the pulley108includes a first opening108XX and a second opening108YY with one opening being used for the left-handed operation and the other being used for the right-handed operation. The cord22is wound on the outer perimeter of the pulley108and is terminated with a knot (not shown). The knot is configured to fit into either of the first opening108XX or the second opening108YY. The guard102is shown inFIG.11Band it not only protects the elements of the clutch mechanism but also forms a smooth path for the cord22from one of the openings108XX,108YY to eyelet108A. As mentioned above, as the cord22is pulled down by wand20, the cord22causes the pulley108to turn. This rotation of the pulley also tightens power spring106. Importantly, as shown inFIG.4, the power spring106is narrow. It is made of a high quality type 301 steel. In one embodiment, it has a thickness of about 0.011 in, a width of about 0.080 in and a length of about 80.5 inches. It can generate a torque of about 0.60 lbf.in. The power spring106is terminated in two respective U-shaped tabs106aand106b. Each tab is about 0.150 in length and has a radius of curvature of about 0.025 in. As shown inFIG.7, pulley108is formed with a curved circumferential slot108Z accessible through a radial channel108ZZ. As can be seen fromFIG.7, the slot108Z extends on either size of channel108ZZ. The channel108ZZ and slot108Z are sized and shaped to receive tab106bof power spring106with the power spring106being wound either clockwise or counterclockwise, depending on whether a right-handed or left-handed operation is used. The pulley108is shaped to form a circular housing for the power spring106, thereby insuring the overall axial dimension of the clutch is as small as possible. The other tab106aof power spring106fits into slot410formed on the internal surface of guard102, as shown inFIG.11B. When the wand20is pulled down, the pulley108is turned by cord22and the clutch mechanism is engaged. Since the guard102is stationary, as the pulley108is rotated by cord22, it winds the power spring106as cord22is pulled down. Once the downward force on the wand20is removed, the clutch mechanism is disengaged and the wound power spring106rotates the pulley108in the opposite direction thereby pulling the cord22up and winding it on the pulley108until the end of wand20proximal to the cord guard102comes in contact with the clutch assembly, which acts as a stop. As shown inFIG.15, the booster assembly200includes: a booster outer sleeve202; a barrel cam tube adapter204; a position stop track member206with a plurality of tracks208; a ball bearing210running in tracks208on the stop track member206; a position stop jacket212; a shaft214shorter than sleeve202; a booster spring216; a free head218; a booster idler tube adaptor220; a booster/decelerator adapter222; a brake or damper224; and a decelerator adapter226. FIG.16shows how many of the components of the booster assembly200are assembled to each other and fit into the booster outer sleeve202. It should be noted that most of the components are arranged in the same manner whether the cord22is disposed on the right or the left side of the system10. However, the position of the booster/decelerator adapter222, the brake or damper224and the decelerator adapter226are reversed when the cord22is on the right side of the system10and some minor changes to assembly configurations may be needed as well without departing from the overall invention. FIGS.17-22show details of the components of the booster assembly200. FIGS.23and24show exploded views of the limiter assembly300. The limiter assembly includes the following components: a bracket cover302; a keyed end bracket304; a retractable pin306; a compression spring308; a spring disk310; limiter wheel springs312; a thumb wheel314; a housing316; spring pins318; a limiter screw320; a limiter stop wheel322; a stop boss324; an idler wheel326; and an adjustment wheel sleeve328. The keyed end bracket304can be secured to an end of the window covering14. FIGS.25to32show details of the components of the limited assembly300.FIG.33illustrates the limiter assembly300in an assembled state. The wand20is shown in further detail inFIGS.34to38. The wand20engages and encloses the end of cord22. As shown inFIG.34, the wand20includes top cap inner23, top cap24, wand body25and bottom cap26.FIGS.35to38show details of the components of wand20. In the embodiment illustrated atFIGS.34to38, the end of cord22passes through top cap inner23where it can, for example, terminate with a knot or other means. The inner cap23can be fixed within top cap24, which is then itself fixed to wand body25, to ensure that the cord22cannot be separated from the wand20. In the illustrated embodiment, the top cap24is fixed to the wand body25by engaging means on each piece. The wand may also include bottom cap26, which is an aesthetic cap attached to the end of the wand body25distal to the cord22. Importantly, at a proximal end of the wand20, the cord22passes through the wand20and immediately enters the clutch assembly100through an eyelet108A (FIG.3) mounted on a bottom surface of the clutch assembly100. The cord22is wound around the pulley108. The spring106and pulley108are arranged to pull the cord22into the clutch assembly whenever it is released (as discussed below) so that the wand20virtually abuts the clutch assembly and the cord22is almost invisible (FIG.14). In this way, the device ensures that the cord22is not normally exposed to cause possible injury to a child. FIG.39shows details of a tool500used to pre-tension the spring216of the booster assembly200. Initially, the spring216is pre-tensioned using the tool500at the factory. In addition, the clutch assembly100features an adjustment shaft130that engages the tool500and the clutch inner member132to the pre-tension spring216. Turning the tool in one direction causes the spring216to be tightened. Turning the tool500in the opposite direction loosens the spring216. At the site, the device including the shade rolled up on tube12(FIG.1) is unpacked and prepped for installation, for example, on a wall, a window frame, etc. As part of this process, the limiter assembly is adjusted to set the desired upper position of the window shade (as described below). This is the position at which the window shade moves when it is released from any lower position. Once the system10is installed, it can be readily used to lower or raise the window covering14as desired either, manually or using the wand20. For the purposes of the discussion below, it is assumed that initially the window covering14is in its upper position. As the wand20pulls on the cord22for a short distance (e.g. about ¼ inch), the window covering14does not move. The reason for this is that within the clutch assembly100, the compression spring120(FIG.3) pushes the clutch sleeve112and the cam drive dog114towards the right and into the core guard cover110and clutch pulley108(e.g., toward a disengaged position). As the cord22is pulled downward and out of the clutch assembly100, the cord22unwinds from clutch pulley108and forces the cam drive dog114and clutch sleeve112to move to the left, against the force of the spring120. As these parts continue to move axially to the left, they come into contact with the crown124. Pulling the cord22further causes the rotation of clutch pulley108to be transmitted to the crown124and the crown124in turn rotates the drive connector136. The drive connector136is inserted into tube12and therefore the rotation of connector136causes the tube12to rotate, thereby lowering the window covering14. Depending on several factors, including the length of the window covering14, the length of cord22, and the desired lower position of window covering14, the window covering14can be lowered using a single stroke of the wand20or multiple up and down strokes. Whenever the tension on the cord22is released, the elements discussed above move back to the right, disengaging from the crown124. Meanwhile the spring106retracts the cord22back into the clutch assembly100and winds it onto the pulley108. The rotation of the tube12is also transmitted to the booster assembly200. As previously mentioned, the spring216is pre-tensioned and tightened as the tube12is rotated to lower the window covering14. The spring216normally provides the force for turning the tube12, raising window covering14. The booster system200is further adapted to provide damping so that the window covering14does not rise too quickly, but instead rises at a substantially constant speed. Finally, the booster system200further provides a break that ensures the tube12and window covering14remain in an intermediate position during the upward stroke of the wand20. The position track stop206and ball bearing210are disposed in the position stop jacket212. This housing is fixed at the end of booster assembly200and it is not allowed to spin freely inside tube12because tube adapter204is keyed into a fixed position and is inserted into an end of the position of track jacket212. The other end of jacket212engages an end of the booster spring216and fixes this spring end so it does not rotate with tube12. Inside the spring jacket, there is a lateral groove arranged to keep the ball bearing210on one of the tracks208and stop it from jumping to other tracks. The position stop track206provides a locking function for the booster assembly200. The tracks208and the ball bearing210cooperate to form a barrel cam with six paths that define six positions for locking and releasing the booster assembly200. As the tube12rotates, the jacket212rotates with the tube12and causes the ball bearing210to follow one of the tracks208. When the tube12stops, the spring216applies a torque on the tube12, thereby forcing the ball bearing210into one of the locking paths208. The shaft214, that can be, for example, comprised of aluminum, is fixed at one end to the position stop track206and at the other end to the free head218in order to provide structural support for the booster assembly. This aids in forming a rigid assembly capable of handling large forces and torques generated by the booster spring216. The free head218is attached to the other end of the booster spring216and is fixed to the shaft214. The adapter220secures the free head218within the tube12, but prevents it from rotating with tube12. Thus, the spring216is tightened by jacket212. Jacket212rotates with tube12, which in turn is rotated by connector136. It was previously noted that in addition to wand20, the system10can be operated by pulling the window covering14down. When the window covering14is released, it moves up slightly until the ball bearing210is trapped in one of the stop tracks208, forcing the window covering14to stop and remain in position. Pulling the window covering14down slightly causes the ball bearing210to disengage and when the window covering14is then released, it is free to move up and roll onto tube12under the influence of spring216. The damper or brake224provides damping to tube12so that it does not spin uncontrollably when the shade14, is released either directly or by wand20, and allowed to move up and wind onto tube12. Details of the limiter assembly300are shown inFIG.23. Idler326and wheel322are connected to screw320and both support and are rotated by tube12. The idler326is free to rotate on the end of the screw320. Wheel322is engaged by the screw320so that as the shade goes up and down, as discussed above, the wheel322moves laterally along the threads of screw320. Initially, the screw320and wheel322are arranged so that when the shade is in its lowest position, the screw320is in its left most position (in the orientation shown inFIG.33) adjacent to the idler326. As the shade is moved up, the wheel322moves to the right toward the end340of screw320. The end340and the wheel322are configured so that when the wheel322reaches the end340, they engage each other, and the wheel322stops rotating, thereby providing an effective stop for the shade. In other words, when the wheel322reaches the end340, the window covering14can no longer move upwards. The thumb wheel314is mechanically coupled to the screw320so that rotating the thumbwheel314causes the screw320to rotate as well. As explained above, in the specific orientation shown inFIGS.33, the end340is the end of screw320that is immediately adjacent to housing316. However, depending on how the item is installed, and whether the fabric is installed to come off the tube behind the roll (as opposed to in front), the end340could refer to the other end of screw320(that is, the end of screw320closest to idler wheel326). The purpose of the limiter assembly300is to allow an operator to select the position of the window covering14beyond which the window covering14does not move. This is accomplished as follows. First, the operator moves the window covering14to the desired position. As previously discussed, as the window covering14moves up, wheel322moves to the right, along screw320towards end340. When the operator stops the window covering14at a desired upper height H0(seeFIG.1), the wheel322reaches a position X along screw320. At this point, the operator turns thumbwheel314causing the screw320to advance to the left through wheel322until end340reaches and engages the wheel322(SeeFIG.2). In this manner the upper limit H0has been set. Of course, next time the window covering14is lowered to its lower limit, the wheel322again travels to the left along screw322, but it no longer reaches the idler326. FIGS.40A-40Bshow an alternate embodiment of the cord guard400. This cord guard400includes a housing402with two holes404,406. The holes404,406are disposed in a wall of the housing402such that they are not horizontal, but rather are offset by an angle that aligns with the direction of cord as the wand20is pulled. This angle may be about 20 degrees. Two rings or eyelets108A (shown inFIG.9) may are disposed in the holes404,406. The cord22operating the window covering14is wound within the guard400and passes through hole404when the window covering14is set for a right handed operation and through hole406when set for a left handed operation. A blanking plug108B may be placed in hole404and hole406when the window covering is set for left and right handed operation, respectively, to cover the hole. This configuration has several advantages. As the cord22is pulled successively through one of the respective holes, the friction between the cord22and the respective hole is reduced substantially. Therefore, the window covering14is easy to operate. In addition, because of this reduced frictional force, the cord22resists fraying or breaking. In the first embodiment shown, for example, inFIG.11B, the hole108X for the cord22is in a central position in order to allow the cord guard102to be used in either left or right-sided operation. This bilateral symmetry is maintained in the present embodiment by providing an area for an eyelet to be inserted in either or both of holes404,406. For both embodiments discussed above for the cord guard102, the spring106shown in detail inFIG.4is formed with two U-shaped ends106a,106b. The spring106is disposed in the core guard in a manner such that end106aengages a slot410(seeFIG.11B) in the central stationary boss104(SeeFIG.3). The other end106bof the spring106is engaged in a slot108Z of pulley108(seeFIGS.6-7). (Slots108XX and108YY shown inFIG.6are used to hold the end of the cord22, one slot being used in the right-side configuration and the other for the left side configuration). Significantly, the slots for holding the ends of the spring106are shaped so that the spring106can be mounted for either operation. As discussed above, in order to raise the window covering14, the cord22is pulled down. This motion causes the pulley108to rotate. Because the spring106is disposed between the stationary boss104and the pulley108, as the pulley108is rotated by the cord22, the pulley108rotates an end of the power spring106, causing the power spring106to tighten. When the cord22is released, the power spring106causes the pulley to reverse direction and rotate in the other direction, thereby pulling the cord22back into the cord guard102. Importantly, the elements of the clutch assembly100and the cord guard102are arranged and constructed to define a space for spring106in such a way that the spring106does not come into contact or rest on any sharp edges, indentations or slots. Rather, the spring106only lies on or comes in contact with smooth rounded surfaces on the pulley108and the cord guard102. It has been found that any discontinuities could cause the spring106to bend with a small radius of curvature or force the coil to twist and distort. Any such bending and distortion of the coil can result in metal fatigue in the spring106and, after repeated operations, the spring106can break at the bending or distortion points. In the present device, these problems are substantially avoided or reduced, thereby increasing the useful life of the spring106and hence the whole system10. In summary, the above-described system10has numerous advantages over other devices known in the art. For example, because of the arrangement and structure of its components, the system10is slimmer and results in a smaller light gap between the system10and the supporting surface. The system10requires a lower pull force to operate, especially under low or no load conditions. The exit point of the cord22from the guard102is formed by an eyelet108A or eyelets that not only presents a low coefficient of friction, but is/are oriented to align more accurately with the cord22as the cord22is pulled in and out of the core guard102. This design reduces the contact surface area, as well as reduces frictional force, thereby reducing the operational force required to raise the window covering14. Moreover, abrasion on the cord22is also reduced, thereby increasing its useful life. The system10(more specifically clutch assembly100) is provided with recessed holes for engaging stationary brackets supporting the system10. This feature further reduces light gaps around the window covering14. The spring used to bias the pulley108is arranged and supported so that it only experiences and applies radial forces, and does not experience any axial forces or other forces that may distort it. The system10is configured to allow access to the clutch mechanism with an appropriate tool (seeFIG.39). The tool extends through a hole formed in the respective end of the clutch assembly100and is used to adjust the booster tension while the system10is installed. The system10can be mounted for either right-handed or left-sided operation and for either forward or reverse operation of the window treatment. The device is provided with an adjustable limiter300to set and adjust a top and/or a bottom stop position for the window shade. This adjustable stop position can be set easily using a thumb wheel314provided on one side of the device. The thumb wheel314can be accessed during or after the installation of the window shade. The limiter300and other components of the device are configured with interlocking members to ensure that the components are snapped together efficiently and securely. The limiter300includes a spring loaded element that is configured so that it does not interfere with the installation or removal of the window shade. Although this invention has been disclosed in the context of certain embodiments and examples, it will be understood by those skilled in the art that the invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. In addition, while several variations of the embodiments of the invention have been shown and described in detail, other modifications, which are within the scope of this invention, including, but not limited to, the substitutions of equivalent features, materials, or parts, will be readily apparent to those of skill in the art based upon this disclosure without departing from the spirit and scope of the invention. | 27,736 |
11859448 | DETAILED DESCRIPTION OF THE INVENTION The embodiments discussed herein are merely illustrative of specific manners in which to make and use the invention and are not to be interpreted as limiting the scope. While the invention has been described with a certain degree of particularity, it is to be noted that many modifications may be made in the details of the invention's construction and the arrangement of its components without departing from the scope of this disclosure. It is understood that the invention is not limited to the embodiments set forth herein for purposes of exemplification. Referring to the drawings in detail,FIG.1illustrates a top view,FIG.2illustrates an end view, andFIG.3illustrates a side view of a rig movement, rotation and alignment assembly10constructed in accordance with the present invention. In a preferred embodiment, the assembly10includes four independent vertical lifting jack assemblies12,14,16and18which are capable of operating independently of each other. The lifting jack assemblies are spaced from and parallel to each other. In a preferred embodiment, four lifting jack assemblies are employed, however, it will be understood that a greater or lesser number might be employed within the spirit of the invention. Each of the lifting jack assemblies12,14,16and18is connected to a rig substructure20. The rig substructure20supports various equipment, a drilling floor, and a mast (not shown). The lifting jack assemblies12,14,16and18are connected to the hydraulic system of the rig by hydraulic lines22. The hydraulic system provides motive force to the lifting jack assemblies. Each of the lifting jack assemblies is operated independently by the hydraulic system of the rig. As will be described herein, each of the vertical lifting jack assemblies12,14,16and18includes a hydraulic cylinder housing50and an elongated extendible and retractable rod52movable axially within the cylinder housing. FIG.4illustrates a top view,FIG.5illustrates a side view,FIG.9illustrates a rear view andFIG.10illustrates a front view of the hydraulic cylinder housing50and elongated rod52. The drawings illustrate and the specification describes one lifting jack assembly12, however, the others are configured in a similar manner. The rod52of each lifting jack assembly moves between an extended and a retracted position. Each rod52is attached at its lower end to a bearing pad as will be described in detail. When the rod52of the lifting jack assembly is extended, the bearing pad rests on the ground. Each of the lifting jack assembles12,14,16and18is also detachably connected near an upper end to the rig substructure20by a pod bracket42,44,46and48, respectively. The rig substructure20supports a drilling rig (not shown). When the rod52of the lifting jack assembly is retracted, the substructure20rests on the ground and the bearing pads are spaced from the ground. Each pod bracket42,44,46and48detachably connects to the substructure20with a pair of extending hooks24and a pair of eyes26. The eyes26are configured to receive pins28which pass through openings in the substructure20in order to securely attach the pod bracket and the lifting jack assembly. Each lifting jack assembly, such as assembly12, includes a cylinder housing50and an elongated rod52concentric with the cylinder housing and movable axially therein. FIG.7illustrates a sectional view taken along section line7-7ofFIG.5showing the elongated rod52within the lifting cylinder housing50. Each lifting jack assembly includes a rod rotation drive assembly. As seen inFIG.7, a screw drive in the form of a slew drive60rotates the elongated rod52with respect to the lifting cylinder housing50. Stated in other words, the cylinder housing50remains stationary and attached to the pod bracket while the rod52rotates. The lower end of each elongated rod52terminates in a convex end which engages with and is retained in a mating top of a roller assembly30. Each roller assembly30includes a roller or a plurality of rollers which engage a flat surface on a roller track. FIG.11illustrates a perspective view of the assembly10with a cap40which has been opened for visibility to illustrate the slew drive60configured to rotate the elongated rod52about its axis in relation to the lifting cylinder housing50. FIG.8illustrates a sectional view taken along section line8-8ofFIG.6. FIG.20illustrates an exploded view of the rig movement, rotation and alignment assembly10, whileFIG.21illustrates an exploded view of the lifting jack assembly12and the bearing pad32. Each lifting assembly includes a rotation translation assembly. With continuing reference toFIG.8and with reference toFIGS.20and21, near a lower end of each elongated rod52is a circumferential recess54. As best seen inFIG.8, the circumferential recess54includes at least one flat segment. In a preferred embodiment, the circumferential recess includes a pair of opposed flat segments56. A retainer plate comprising a pair of arcuate retainer plates58together surround the elongated rod52and reside in the circumferential recess54. The arcuate retainer plates58also have flat segments which mate with the flat segments56in the circumferential recess54of the elongated rod. Accordingly, the retainer plates58trap the elongated rod52. The retainer plates58are, in turn, secured to the roller assembly30which, in turn, is secured to the bearing pad32. The roller assembly30permits incremental movement of the cylinder and rod52with respect to the bearing pad32by a pair of parallel hydraulic skidding cylinders62. When the bearing pad32is lowered on the ground, the skidding cylinders62are configured to move the entire rig substructure with respect to the bearing pad32. The elongated rod52is, thus, connected to the bearing pad32through the roller assembly. Accordingly, rotational movement of the rod52results in rotational movement of the roller assembly30and, in turn, the bearing pad32. FIG.6is a sectional view taken along section line6-6ofFIG.5. As seen inFIGS.6and8, there is an inverted V-shaped track64between the bearing pad32and the roller assembly30above it which permits lateral realignment of each bearing pad. FIG.13illustrates a perspective view of the rig movement, rotation and alignment assembly10shown inFIGS.1through12.FIGS.14,15, and16illustrate alternate views of the bearing pad32rotated in a position90degrees from the position of the bearing pad32shown inFIGS.1through13. FIGS.17,18, and19illustrate the bearing pad32rotated to a different rotational orientation with respect to the cylinder housing50and pod bracket42shown inFIGS.1through16. While the foregoing describes operation of one lifting jack assembly, the others operate in similar fashion. The present invention thus provides direct transfer of rotational movement of the elongated rod of the hydraulic cylinder housing to the bearing pad without complicated linkage or other mechanisms. At the same time, the bearing pad is incrementally movable with respect to the hydraulic lifting cylinder and elongated rod. Whereas, the invention has been described in relation to the drawings attached hereto, it should be understood that other and further modifications, apart from those shown or suggested herein, may be made within the scope of this invention. | 7,315 |
11859449 | DETAILED DESCRIPTION In the following detailed description, certain specific details are set forth to provide a thorough understanding of various disclosed implementations and embodiments. However, one skilled in the relevant art will recognize that implementations and embodiments may be practiced without one or more of these specific details, or with other methods, components, materials, and so forth. For the sake of continuity, and in the interest of conciseness, same or similar reference characters may be used for same or similar objects in multiple figures. As used herein, the term “coupled” or “coupled to” or “connected” or “connected to” “attached” or “attached to” may indicate establishing either a direct or indirect connection, and is not limited to either unless expressly referenced as such. As used herein, fluids may refer to slurries, liquids, gases, and/or mixtures thereof. It is to be further understood that the various embodiments described herein may be used in various stages of a well (land and/or offshore), such as rig site preparation, drilling, completion, abandonment etc., and in other environments, such as work-over rigs, fracking installation, well-testing installation, oil and gas production installation, without departing from the scope of the present disclosure. Embodiments disclosed herein are directed to a downhole sub for releasing of one or more mobile devices in a downhole environment. More specifically, embodiments disclosed herein are directed to a downhole sub having a swappable housing, storing one or more mobile devices, and a control element made of dissolvable material for trigging the release of the one or more mobile devices from the housing in a downhole environment. The different embodiments described herein may provide a downhole sub in a bottom-hole assembly (BHA) of a drilling string during drilling operations for deployment of one or more mobile devices that plays a valuable and useful role in the life of a well. By using the downhole sub for deployment of one or more mobile devices, the downhole sub may eliminate the need for deploying the one or more mobile devices from the surface and other costly surface facilities conventionally used in mobile device deployment. Further, a configuration and arrangement of the downhole sub to deploy the one or more mobile devices in the downhole environment according to one or more embodiments described herein may provide a cost-effective alternative to conventional methods. For example, one or more embodiments described herein may eliminate the need for costly surface facilities conventionally used in mobile device deployment operations. The embodiments are described merely as examples of useful applications, which are not limited to any specific details of the embodiments herein. In accordance with one or more embodiments, a downhole sub includes a compartment extending a depth from an outer surface and a housing is removable fixed in the compartment. In one or more embodiments, the housing holds one or more mobile devices. Each of the mobile devices are a sensor encapsulated in a protective material. Further, a control element blocks an opening of the housing and is made of a dissolvable material configured to dissolve at a depth in a wellbore to release the one or more mobile devices into the downhole environment. In conventional methods, downhole mobile devices are dropped from the surface at a top of a drill string to be carried by the flow of the drilling fluid to reach a bottom of the drill string at a bottom-hole assembly (BHA). Then, the downhole mobile devices continue flowing through drilling bit nozzles to an open-hole annulus, and then travel up with the drilling fluid flow to a cased-hole annulus, and finally, to surface where the downhole mobile devices are recovered for data download. The conventional method of deploying the downhole mobile devices give rise to a number of problems such as a significant portion of the downhole mobile devices' battery life can be lost before actually pass through the drilling bit to record data of in-situ conditions along the open-hole annulus. Another problem occurs in drilling sections with a small drill bit where the jet nozzles on the bit are small and may become blocked by the downhole mobile devices and be too big to pass through the jet nozzles. Additionally, an internal flow path restriction of the downhole mobile devices can also come from internal profiles of different BHA components and the drill string, as the downhole mobile devices may block the flow path of various fluids such as drilling fluids. Advantageously, the downhole sub disclosed herein may deploy one or more mobile devices in a downhole environment without requiring surface equipment and avoid internal profiles of different BHA components and the drill string used in typical mobile devices deployment operations. Moreover, because the deployment of the one or more mobile devices occurs fully underground, the disclosed method deploys the one or more mobile devices into the annulus directly thereby eliminating the potential hazard of the one or more mobile devices getting stuck within the internal profiles of different BHA components and the drill string as well as enhance the battery life and electrical charging efficiency of the one or more mobile devices. Overall, the downhole sub disclosed herein may minimize product engineering, risk associated with surface equipment, reduction of assembly time, hardware cost reduction, and weight and envelope reduction. Thus, the disclosed the deployment methods of one or more mobile devices using the downhole sub improves safety on site and reduces cost associated with conventional mobile devices deployment operations. FIG.1illustrates an exemplary well site100. In general, well sites may be configured in a myriad of ways. Therefore, well site100is not intended to be limiting with respect to the particular configuration of the drilling equipment. The well site100is depicted as being on land. In other examples, the well site100may be offshore, and drilling may be carried out with or without use of a marine riser. A drilling operation at well site100may include drilling a wellbore102into a subsurface including various formations104,106. For the purpose of drilling a new section of wellbore102, a drill string108is suspended within the wellbore102. The drill string108may include one or more drill pipes109connected to form conduit and a bottom hole assembly (BHA)110disposed at the distal end of the conduit. The BHA110may include a drill bit112to cut into the subsurface rock. The BHA110may also include various directional drilling tools and wellbore expanders, such as a mud motor116and a reamer117, to direct the path at which the drill bit112cuts into the subsurface rock. The BHA110may further include measurement tools114, such as a measurement-while-drilling (MWD) tool and logging-while-drilling (LWD) tool. The measurement tools114may include sensors and hardware to measure downhole drilling parameters, and these measurements may be transmitted to the surface using any suitable telemetry system known in the art. The BHA110and the drill string108may include other drilling tools known in the art but not specifically shown. In one or more embodiments, the BHA110also includes a downhole sub300to deploy one or more mobile device within the wellbore102. The downhole sub300may be located at various positions along the BHA110. For example, the downhole sub300may be positioned above the drill bit112and coupled between the drill bit112and the mud motor116. At the position between the drill bit112and the mud motor116, the downhole sub300deploys one or more mobile devices to measure an area of the wellbore102near the drill bit112. Additionally, this position of the downhole sub300eliminates the risks associated with the one or more mobile devices passing through the tight spots in the wellbore102where downhole tools, such as the reamer117, are normally mounted next to the mud motor116. Alternatively, the downhole sub300or a second downhole sub may be positioned above the mud motor116, the measurement tools114, or the reamer117. The one or more mobile devices are stored in a housing removably coupled to the downhole sub300. From the housing, the downhole sub300will deploy the one or more mobile devices into the wellbore102at a predetermined depth to record and transmit various downhole measurements. To deploy the one or more mobile devices, the downhole sub300includes a control element made of a dissolvable material. Initially, the control element blocks an opening of the housing storing the one or more mobile devices. Once the downhole sub300reaches the predetermined depth, the control element dissolves to no longer block the opening of the housing such that the one or more mobile devices are deployed into the downhole environment of the wellbore102. In a non-limiting example, the predetermined depth may be a bottom of a section of the wellbore102that is finished drilling to maximize a covered path of a logging operation. Alternately, the predetermined depth may be a depth of downhole interests both in terms of positions and time domain events, such as a tight spot, loss circulation, stuck pipe, drill pipe leakage, casing leakage, cementing, or various other downhole points. In some embodiments, the control element is made of a dissolvable material tailored by adjusting chemical compositions, processing and surface modifications, dissolvable material grades, or thickness to produce a dissolving rate specific to downhole conditions at the predetermined depth. In one or more embodiments, the one or more mobile devices are stored in the housing in a standby mode while the downhole sub300is run downhole. The one or more mobile devices may be taken out of standby mode to record and transmit various downhole measurements in a variety of techniques. For example, the one or more mobile devices may have a time delay to time and sync the one or more mobile devices to exit out of standby mode when the downhole sub300reaches the predetermined depth. Additionally, a temperature measurement may be used to take the one or mobile devices out of standby mode by determining the moment of deployment through detecting a temperature change. Further, the one or mobile devices may exit standby mode through a change of motion, such as, the one or more mobile devices accelerating. The drill string108may be suspended in wellbore102by a derrick118. A crown block (120) may be mounted at the top of the derrick118, and a traveling block122may hang down from the crown block120by means of a cable or drilling line124. One end of the cable124may be connected to a drawworks126, which is a reeling device that may be used to adjust the length of the cable124so that the traveling block122may move up or down the derrick118. The traveling block122may include a hook128on which a top drive130is supported. The top drive130is coupled to the top of the drill string108and is operable to rotate the drill string108. Alternatively, the drill string108may be rotated by means of a rotary table (not shown) on the drilling floor131. Drilling fluid (commonly called mud) may be stored in a mud pit132, and at least one pump134may pump the mud from the mud pit132into the drill string108. The mud may flow into the drill string108through appropriate flow paths in the top drive130(or a rotary swivel if a rotary table is used instead of a top drive to rotate the drill string108). In one implementation, a system200may be disposed at or communicate with the well site100. System200may control at least a portion of a drilling operation at the well site100by providing controls to various components of the drilling operation. The System200may be a computing system, as described inFIG.8. In one or more embodiments, system200may receive data from the one or more mobile devices deployed from the downhole sub300and one or more sensors160arranged to measure controllable parameters of the drilling operation. As a non-limiting example, the one or more mobile devices and the one or more sensors160may be arranged to measure WOB (weight on bit), RPM (drill string rotational speed), GPM (flow rate of the mud pumps), and ROP (rate of penetration of the drilling operation). The one or more sensors160may be positioned to measure parameter(s) related to the rotation of the drill string108, parameter(s) related to travel of the traveling block122, which may be used to determine ROP of the drilling operation, and parameter(s) related to flow rate of the pump134. For illustration purposes, the one or more sensors160are shown on drill string108and proximate mud pump134. The illustrated locations of the one or more sensors160are not intended to be limiting, and the one or more sensors160could be disposed wherever drilling parameters need to be measured. Moreover, there may be many more sensors160than shown inFIG.1to measure various other parameters of the drilling operation. Each sensor160may be configured to measure a desired physical stimulus. During a drilling operation at the well site100, the drill string108is rotated relative to the wellbore102, and weight is applied to the drill bit112to enable the drill bit112to break rock as the drill string108is rotated. In some cases, the drill bit112may be rotated independently with a drilling motor. In further embodiments, the drill bit112may be rotated using a combination of the drilling motor and the top drive130(or a rotary swivel if a rotary table is used instead of a top drive to rotate the drill string108). While cutting rock with the drill bit112, mud is pumped into the drill string108. The mud flows down the drill string108and exits into the bottom of the wellbore102through nozzles in the drill bit112. The mud in the wellbore102then flows back up to the surface in an annular space between the drill string108and the wellbore102with entrained cuttings. The mud with the cuttings is returned to the pit132to be circulated back again into the drill string108. Typically, the cuttings are removed from the mud, and the mud is reconditioned as necessary, before pumping the mud again into the drill string108. In one or more embodiments, the drilling operation may be controlled by the system200. Referring toFIG.2A, the downhole sub300in accordance with embodiments disclosed herein is illustrated. For illustration purposes, the downhole sub300is shown in an exploded view to illustrate a housing301and a compartment302. the downhole sub300includes a body303defined by a wall304extending a length L in an axial direction from a first end305to a second end306. The first end305and the second end306are connection ends to allow the downhole sub300to be coupled to various components in the BHA (for example, the drill bit, the directional drilling tool, or any tools in the BHA). Additionally, an inner surface304aof the wall304defines a flow path through the downhole sub300and an outer surface304bof the wall304defines an outer diameter of the downhole sub300. In one or more embodiments, the compartment302extends a depth D from the outer surface30binto the wall304. The depth D of the compartment302is less than a thickness T of the wall304. For example, the depth D of the compartment302may be within the range of a minimal value that allows for storing one or more mobile devices (320) and a maximum value with which a minimum cavity bottom wall is required to maintain a structural integrity of the downhole sub300. The depth D of the compartment302may have a value above 5 mm and below the thickness T of the wall304. In some embodiments, the depth D of the compartment302may be based on half of the thickness T of the wall304(for example, the depth D of the compartment302may be determined by ½*(Outer Diameter−Inner Diameter)). Additionally, the compartment302also extends a length L2in the axial direction shorter than the length L of the wall304. Further, the compartment302also extends a width W in a radial direction. The compartment302may be milled vertically from a side of the downhole sub300with the width W and the length L2. For example, the width W may be determined by a needed size of the compartment302and a size limitation of the downhole sub300. The width W may have a value of above 5 mm and below the outer diameter of downhole sub300. As shown inFIG.2A, the housing301may have a dimensional profile matching a dimensional profile of the compartment302to have the housing301fit into the compartment302. For example, the housing301may have a thickness T2equal to the depth D of the compartment302, a length L3equal to the length L2of the compartment302, and a width W2equal to the width W of the compartment302. While it is noted that the housing301and the compartment302are shaped in a rectangle, this is merely for example purposes, and the housing301and the compartment302may be in any shape without departing from the present scope of the disclosure. In one or more embodiments, the housing301includes one or more connection points308aligned with one or more connection points309on a surface307of the compartment302. For example, the one or more connection points308,309may be holes for a mechanical fastener310(for example, a bolt, nail, or screw) to removably fix the housing301within the compartment302. Alternatively, a magnet or adhesive may be used to removably fix the housing301within the compartment302. Still referring toFIG.2A, the housing301includes an opening311on a top surface312. A control element313is shaped to be inserted into the opening311. For example, the control element313may be in the form of a plug to fit within and close the opening311. Additionally, a connection surface314of the control element313is coupled to a connection surface315within the opening311. Both connection surfaces314,315may be threaded connections. The control element313is made of a dissolvable material with metallic or non-metallic based materials. The metallic dissolvable material may be a magnesium based alloy or an aluminum based alloy. The non-metallic dissolvable material may be polyglycolic acid (PGA), polylactic acid (PLA), or polyurethane (PU). One skilled in the art will appreciate how the dissolvable materials may be tailored by adjusting the chemical compositions, processing and surface modifications to produce a dissolving rate of the control element313in specific downhole conditions at the predetermined depth. It is further envisioned that the control element313may be made of different dissolvable material grades, thickness, or surface modifications to achieve a targeted deployment timing of the one or more mobile devices at the predetermined depth due to different downhole conditions. In some embodiments, at an end opposite the opening311, the housing301may include a cutout portion316recessed lower than the top surface312. In the cutout portion316, a fluid inlet317is provided to allow fluid to flow into the housing301to aid in deploying the one or more mobile devices out of the opening311. Additionally, a ledge318may be formed between the top surface312and the cutout portion316. The ledge318may form a back stop for fluids to buildup and flow into the fluid inlet317. Now referring toFIG.2B, the downhole sub300is illustrated with the housing301removably fixed in the compartment302and the control element313inserted into the opening311. The housing301fits into the compartment302such that the top surface312of the housing301is flush with the outer surface304bof the wall304. Additionally, the top surface312may be curved to match the cylindrical shape of the downhole sub300. InFIGS.2C and2D, a cross-sectional view of the downhole sub300taken along line2-2inFIG.2Bis illustrated. The first end305may be a box threaded connection and second end306may be a pin threaded connection. The inner surface304aof the wall304may have an inner diameter ID to allow fluids (for example, drilling fluids such as mud) travel through the flow path of the downhole sub300. In one or more embodiments, the housing301includes a storage compartment319to store one or more mobile devices320. The one or more mobile devices320may be disposed in the storage compartment319via a bottom surface327of the housing301. The storage compartment319may be sealed by the top surface312and a back lid321. Additionally, the storage compartment319is fluidly coupled to the fluid inlet317such that fluids flow into the storage compartment from the fluid inlet317. For example, fluids are guided to the fluid inlet317via the ledge118to flow into the storage compartment319. As shown inFIG.2C, the control element313has a length Lc to seal against the back lid321to close off the storage compartment319. When fully inserted, the control element313is slightly below the top surface312to avoid contacting the wellbore preventing damage to the control element313which may result in deploying the one or more mobile devices320before the predetermined depth is reached. In some embodiments, each of the one or more mobile devices320is a sensor encapsulated in a protective material. The protective material may be a polymer based composite material, epoxy material, or a combination thereof. The one or more mobile devices320may be in various shaped in various profiles (for example, spherical, pill, bullet, and other shapes) and sizes (for example, submillimeter to tens and up to a few hundred millimeters in diameter) to fit within the storage compartment319. Additionally, the one or more mobile devices320are compact, lightweight, and stand-alone systems, with millimeter-range footprint, that are used to collect downhole in-situ data respective to the sensor encapsulated in the protective material. For example, the sensors embodied as the one or more mobile devices320may be acoustic sensors, pressure sensors, vibration sensors, accelerometers, gyroscopic sensors, magnetometer sensors, and temperature sensors. The one or more mobile devices320measure/collect downhole measurements such as wellbore directional survey, temperature profile, or pressure profile to provide an inexpensive solution for taking measurements downhole. Additionally, the one or more mobile devices320are configured to transmit the collected downhole measurements to the surface without the need for additional trips into the wellbore for different types or for additional measurements. The collected downhole measurements may be used to analyze, control, monitor, and/or optimize aspects of the drilling operation and facilitate relevant decision-making in real-time. In one or more embodiments, the one or more mobile devices320may be charged with the use of a powering unit within the downhole sub300. For example, the housing301may include electronics for downhole charging and initiation of the one or more mobile devices320. The electronics may include transmitter coil(s), control unit(s), and/or battery cell(s) to enable continuous charging (wired or wireless) of the one or more mobile devices320through a charging interface. The electronics may also include accelerometers and/or other sensors along with microcontrollers to trigger the initiation of the one or more mobile devices320to switch from standby (or sleep) mode to active (or on) mode which starts in-situ data collection. Now referring toFIG.3, for illustration purposes, the housing301is shown in an exploded view. The back lid321may have a length L4equal to the length L3of the housing301. Additionally, the housing301may have a slot322in the bottom surface327for the back lid321to fit into. The back lid321may include one or more connection holes323for a mechanical fastener324(for example, a bolt, nail, or screw) to removably fix the back lid321in the slot322. In one or more embodiments, the ledge318has a profile of a semicircular groove to guide fluid to the fluid inlet318. The ledge318may progressively increase in size/width from ends318aof the semicircular groove to a vertex318bof the semicircular groove. For example, the ledge318may have a height equal to the cutout portion316at the ends318aand progressively get bigger such that the height of the ledge318at the vertex318bis equal to the top surface312. Additionally, the fluid inlet318may extend from the cutout portion316to a portion of the ledge318. Further, the fluid inlet318may include a filter325to prevent debris and solids from entering the storage compartment319. As shown inFIG.3, the opening311may be circular with a diameter DO. Additionally, the control element313may be a plug with a cylindrical shape match the circular profile of the opening311. For example, the control element313may have a diameter DC equal to the diameter DO of the opening311such that the control element313blocks the opening311. Additionally, to insert and tighten the control element313in the opening311, the control element313may include a torque connection326, such as a drive or recess, for a torque tool to engage. For example, the torque connection326may be torqued to couple the connection surface314of the control element313to the connection surface315within the opening311. Both connection surfaces314,315may be threaded connections. Alternatively, both connection surfaces314,315may be grated surfaces or sized to form a friction fit between the control element313and the opening311. Now referring toFIGS.4A-4C, a workflow of the downhole sub300described inFIGS.2A-3is illustrated. InFIG.4A, the downhole sub300is assembled and run downhole in the wellbore. The assembly of the downhole sub300may take place at the surface. For example, the one or more mobile devices (320) may be placed in the storage compartment (319) and the back lid (321) is removably fixed in the slot (322) of the housing301. Additionally, the control element313is inserted into the opening311. Next, the housing301is removably fixed in the compartment (302) to fully assembly the downhole sub. Once the downhole sub300reaches the predetermined depth, the control element (313) dissolves to open the opening311, as shown in theFIG.4B. With the control element (313) dissolved, fluids may enter the storage compartment (319) of the housing301via the fluid inlet317and flow the one or more mobile devices320out of the opening311, as shown in theFIG.4C. The one or more mobile devices320are deployed directly into an annulus between the wellbore and BHA to record and transmit downhole measurements. From the annulus, drilling fluids may carry the one or more mobile devices320back to the surface. Now referring toFIG.5A, another embodiment of the downhole sub300according to embodiments herein is illustrated, where like numerals represent like parts. The embodiment ofFIG.5Ais similar to that of the embodiment ofFIG.2A. However, in the embodiment ofFIG.5A, the control element313may be a lid covering the storage compartment319of the housing301instead of being a plug inserted in the opening (311ofFIG.2A). Additionally, the storage compartment319may include one or more steps530to delimit a storage space of the storage compartment319holding the one or more mobile devices320. Further, the control element313includes one or more connection points531aligned one or more connection points532on the one or more steps530. For example, the one or more connection points531,532may be holes for a mechanical fastener533(for example, a bolt, nail, or screw) to couple the control element313within the storage compartment319. Alternatively, a magnet or adhesive may be used to removably fix the control element313within the storage compartment319. It is further envisioned that the control element313may include an equalization port534for pressure equalization at two sides of the control element313at any time. Now referring toFIG.5B, the downhole sub300is illustrated with the housing301removably fixed in the compartment302. Additionally, the control element313is inserted into the storage compartment319to be flush with the top surface312of the housing301. The housing301fits into the compartment302such that the top surface312of the housing301is flush with the outer surface304bof the wall304. Additionally, the top surface312and the control element313may be curved to match the cylindrical shape of the downhole sub300. InFIG.5C, a cross-sectional view of the downhole sub300taken along line5-5inFIG.5Bis illustrated. The first end305may be a box threaded connection and second end306may be a pin threaded connection. The inner surface304aof the wall304may have an inner diameter ID to allow fluids (for example, drilling fluids such as mud) travel through the flow path of the downhole sub300. Additionally, the housing301includes the storage compartment319to store one or more mobile devices320. The storage compartment319is delimited by the control element313and a bottom535of the housing301. As shown inFIG.5C, the control element313has a length Lc2equal to a length Ls of the storage compartment319. When fully inserted, the control element313fully covers the storage compartment319to store the one or more mobile devices320. Additionally, the control element313has a thickness Tc extending from a first surface to a second surface537which may be adjusted depending on the predetermined depth. The equalization port534may extend from the first surface536of the control element313to the second surface537of the control element313. The equalization port534may be used for pressure equalization in the storage compartment319and outside of the control element313. Now referring toFIGS.6A-6C, a workflow of the downhole sub300described inFIGS.5A-5Cis illustrated. InFIG.6A, the downhole sub300is assembled and run downhole in the wellbore. The assembly of the downhole sub300may take place at the surface. For example, the one or more mobile device (320) may be placed in the storage compartment (319) and the control element313is removably fixed in the storage compartment (319) to close in the one or more mobile device (320). Next, the housing301removably fixed in the compartment (302) to fully assembly the downhole sub. Once the downhole sub300reaches the predetermined depth, the control element313dissolves, to open the storage compartment319and expose the one or more mobile devices320, as shown inFIG.6B. With the control element313dissolved, the one or more mobile devices320are deployed directly into an annulus between the wellbore and BHA to record and transmit downhole measurements, as shown in theFIG.6C. In one or more embodiments, the control element may dissolve, trigging the release of the mobile devices, at a set time and set downhole environment. From the annulus, drilling fluids may carry the one or more mobile devices320back to the surface via back flow, for example. Now referring toFIG.9, a cross sectional view of the one or more mobile devices320is illustrated. The one or more mobile devices320are sensors950encapsulated in a protective material951. The protective material951may be a polymer based composite material, epoxy material, or a combination thereof. The protective material951may form a shell in the shape of sphere. However, the shape of the shell may have various profiles (for example, spherical, pill, bullet, and other shapes) and sizes (for example, submillimeter to tens and up to a few hundred millimeters in diameter) to fit within the storage compartment (319). Additionally, the one or more mobile devices320are compact, lightweight, and stand-alone systems, with millimeter-range footprint, that are used to collect downhole in-situ data respective to the sensor950encapsulated in the protective material951. The sensor950embodied as the one or more mobile devices320may be acoustic sensors, pressure sensors, vibration sensors, accelerometers, gyroscopic sensors, magnetometer sensors, and temperature sensors. Further, within the protective material951, the sensor950may be provided on a printed circuit board952. Additionally, a microprocessor953and a battery954may be in communication with the sensor950via the printed circuit board952. Now referring toFIG.10, a cross sectional view of the housing301without the one or more mobile devices (320) is illustrated. In the storage compartment319, the housing301may include a charging pad960to charge the one or more mobile devices (320). For example, the one or more mobile devices (320) may be directly contacting the charging pad960to receive a charge. Additionally, an electronic connection961may connect the charging pad960to a circuit962and a battery963for charging and initiation of the one or more mobile devices (320). The circuit962and the battery963may be hermetically sealed in a separate compartment964from the storage compartment319containing the charging pad960. By hermetically sealing the circuit962and the battery963in the separate compartment964, fluids are prevented from damaging the circuit962and the battery963. The charging pad960, the electronic connection961, the circuit962, and the battery963may form a power unit to enable continuous charging (wired or wireless) of the one or more mobile devices (320) and trigger the initiation of the one or more mobile devices (320) to switch from standby (or sleep) mode to active (or on) mode which starts in-situ data collection. FIG.7is a flowchart showing a method for deploying the one or more mobile devices using the downhole sub300described inFIGS.1-6C,9, and10. One or more blocks inFIG.2may be performed by one or more components, such as, a computing system coupled to a controller in communication with the downhole sub300. For example, a non-transitory computer readable medium may store instructions on a memory coupled to a processor such that the instructions include functionality for operating the downhole sub300. While the various blocks inFIG.2are presented and described sequentially, one of ordinary skill in the art will appreciate that some or all of the blocks may be executed in different orders, may be combined or omitted, and some or all of the blocks may be executed in parallel. Furthermore, the blocks may be performed actively or passively. In Block700, the downhole sub is assembled. To assemble the downhole sub, the one or more mobile devices are disposed into the storage compartment of the housing. For example, the one or more mobile devices may be placed into the storage compartment from the bottom surface of the housing, the back lid is removably fixed to the slot in the bottom surface, and the control element (in the form of a plug) is inserted into the opening in the top surface to seal the one or more mobile devices in the storage compartment. Alternatively, the one or more mobile devices may be placed into the storage compartment from the top surface of the housing and the control element (in the form of a lid) is inserted into the storage compartment to seal the one or more mobile devices in the storage compartment. Additionally, the one or more mobile devices may be directly contacting a charging pad in the storage compartment. Further, when the one or more mobile devices are disposed in the storage compartment, the one or more mobile devices are in a standby mode. With the one or more mobile devices sealed in the storage compartment, the housing is removably fixed within the compartment to fully assemble the downhole sub. In Block701, the downhole sub is coupled to the BHA. For example, the downhole sub is coupled to the components of the BHA to be position axially above the drill bit of the BHA. In one or more embodiments, the downhole sub may directly be coupled to the drill bit or be axially spaced above the drill bit. With the BHA formed, the drill string may be coupled to the BHA to lower the BHA into the well and drill the formation to form the wellbore. In one or more embodiments, the downhole sub is mounted on a nozzle which may be used for any drilling bit without customized bit manufacturing. In Block702, with the downhole sub assembled and coupled the BHA, the downhole sub is lowered into the wellbore via the drill sting and drilling operations are conducted at the well site. For example, the drill string is rotated, and weight is applied to the drill bit to enable the drill bit to drill the formation as the drill string is rotated. In some cases, the drill bit may be rotated independently of the drill string. While drilling the formation, mud is pumped into the drill string and out the drill bit to flow cutting up the annulus between the wellbore and drill string to reach the surface. Furthermore, as the downhole sub is lowered, the one or more mobile devices are continuously charging via the charging pad that is being powered by the circuit and the battery through the electronic connection. In Block703, with the drilling operations taking place, the downhole sub will reach a predetermined depth in the wellbore. For example, the predetermined depth may be a bottom of a section of the wellbore or a depth of downhole interest both in terms of positions and time domain events, such as a tight spot, loss circulation, stuck pipe, drill pipe leakage, casing leakage, cementing, or various other downhole points. In Block704, with the downhole sub at the predetermined depth, the control element dissolves. For example, once the control element is exposed to the downhole conditions at the predetermined depth, the control element dissolves to open the storage compartment. The control element is made of a dissolvable material tailored by adjusting chemical compositions, processing and surface modifications, dissolvable material grades, and/or thickness to produce a dissolving rate specific to downhole conditions at the predetermined depth. In alternate embodiments, the control element on the downhole sub may dissolve based on a timed event, such as a timer that is affixed to the downhole sub. In Block705, after the control element is dissolved, the one or more mobile devices are deployed into the wellbore. For example, the one or more mobile devices exit the storage compartment to release directly into the annulus between the wellbore and drill string. In some embodiments, fluids enter the storage compartment via the fluid inlet and flow out the one or more mobile devices through the opening in the top surface of the housing. Alternatively, the one or more mobile devices may flow directly out of the storage compartment without needing fluid to push out the one or more mobile devices. In Block706, the one or more mobile devices start to measure and/or collect downhole measurements at the predetermined depth. To collect downhole measurements, the one or more mobile devices are taken out of standby mode to be turned on to record and collect the downhole measurements. For example, the one or more mobile devices may have a time delay to time and sync the one or mobile devices to be taken out of standby mode when the downhole sub reaches the predetermined depth. Additionally, by determining the moment of deployment through detecting a temperature change (for example, the downhole temperature relative to the temperature in the storage compartment), a temperature measurement may be used to take the one or more mobile devices out of standby mode. Further, the one or mobile devices may be taken out of standby mode through a change of motion, such as, when the one or more mobile devices are accelerating out of the storage compartment. In Block707, the one or more mobile devices transmits the collected downhole measurements to the surface to analyze, control, monitor, and/or optimize aspects of the drilling operation and facilitate relevant decision-making based on the collected downhole measurements. For example, the one or more mobile devices may include telemetry to transmit the collected downhole measurements to the surface in real-time. Additionally, the one or more mobile device may include a memory to store the collected downhole measurements. With the collected downhole measurements stored on the one or more mobile device, drilling fluids may be pumped down the drill string and exit the BHA into the annulus. In the annulus, the drilling fluids continue to flow upward and into a drilling fluid reservoir at the surface. The drilling fluids will carry the one or more mobile devices to the surface for collection. Upon collecting the one or more mobile devices at the surface from the drilling fluid reservoir, the stored collected downhole measurements may be uploaded for analyzation. In addition to the benefits described above, the downhole sub may improve an overall efficiency and performance of drilling operations while reducing cost and risk of non-productive time (NPT), and many other advantages. Further, the downhole sub may provide further advantages such as being able to deploy the one or more mobile devices directly into the annulus, avoid costly fishing operations as the one or more mobile devices does not travel through the drill bit and other BHA components, being used in drilling operations that require small bit nozzles sizes that cannot have the one or more mobile devices pass through, and is not limited to any type of well operations (for example, drilling, well testing and surveying, hydraulic fracturing, workover, and completions on either offshore or land rigs). Embodiments may be implemented on a computer system.FIG.8is a block diagram of a computer system802used to provide computational functionalities associated with described downhole sub300, methods, functions, processes, flows, and procedures as described in the instant disclosure, according to an implementation. The illustrated computer802is intended to encompass any computing device such as a high-performance computing (HPC) device, a server, desktop computer, laptop/notebook computer, wireless data port, smart phone, personal data assistant (PDA), tablet computing device, one or more processors within these devices, or any other suitable processing device, including both physical or virtual instances (or both) of the computing device. Additionally, the computer802may include a computer that includes an input device, such as a keypad, keyboard, touch screen, or other device that can accept user information, and an output device that conveys information associated with the operation of the computer802, including digital data, visual, or audio information (or a combination of information), or a GUI. The computer802can serve in a role as a client, network component, a server, a database or other persistency, or any other component (or a combination of roles) of a computer system for performing the subject matter described in the instant disclosure. The illustrated computer802is communicably coupled with a network830. In some implementations, one or more components of the computer802may be configured to operate within environments, including cloud-computing-based, local, global, or other environment (or a combination of environments). At a high level, the computer802is an electronic computing device operable to receive, transmit, process, store, or manage data and information associated with the described subject matter. According to some implementations, the computer802may also include or be communicably coupled with an application server, e-mail server, web server, caching server, streaming data server, business intelligence (BI) server, or other server (or a combination of servers). The computer802can receive requests over network830from a client application (for example, executing on another computer802) and responding to the received requests by processing the said requests in an appropriate software application. In addition, requests may also be sent to the computer802from internal users (for example, from a command console or by other appropriate access method), external or third-parties, other automated applications, as well as any other appropriate entities, individuals, systems, or computers. Each of the components of the computer802can communicate using a system bus803. In some implementations, any or all of the components of the computer802, both hardware or software (or a combination of hardware and software), may interface with each other or the interface804(or a combination of both) over the system bus803using an application programming interface (API)812or a service layer813(or a combination of the API812and service layer513. The API812may include specifications for routines, data structures, and object classes. The API812may be either computer-language independent or dependent and refer to a complete interface, a single function, or even a set of APIs. The service layer813provides software services to the computer802or other components (whether or not illustrated) that are communicably coupled to the computer802. The functionality of the computer802may be accessible for all service consumers using this service layer. Software services, such as those provided by the service layer813, provide reusable, defined business functionalities through a defined interface. For example, the interface may be software written in JAVA, C++, or other suitable language providing data in extensible markup language (XML) format or other suitable format. While illustrated as an integrated component of the computer802, alternative implementations may illustrate the API812or the service layer813as stand-alone components in relation to other components of the computer802or other components (whether or not illustrated) that are communicably coupled to the computer802. Moreover, any or all parts of the API812or the service layer813may be implemented as child or sub-modules of another software module, enterprise application, or hardware module without departing from the scope of this disclosure. The computer802includes an interface804. Although illustrated as a single interface804inFIG.8, two or more interfaces804may be used according to particular needs, desires, or particular implementations of the computer802. The interface804is used by the computer802for communicating with other systems in a distributed environment that are connected to the network830. Generally, the interface804includes logic encoded in software or hardware (or a combination of software and hardware) and operable to communicate with the network830. More specifically, the interface804may include software supporting one or more communication protocols associated with communications such that the network830or interface's hardware is operable to communicate physical signals within and outside of the illustrated computer802. The computer802includes at least one computer processor805. Although illustrated as a single computer processor805inFIG.8, two or more processors may be used according to particular needs, desires, or particular implementations of the computer802. Generally, the computer processor805executes instructions and manipulates data to perform the operations of the computer802and any algorithms, methods, functions, processes, flows, and procedures as described in the instant disclosure. The computer802also includes a memory806that holds data for the computer802or other components (or a combination of both) that can be connected to the network830. For example, memory806can be a database storing data consistent with this disclosure. Although illustrated as a single memory806inFIG.8, two or more memories may be used according to particular needs, desires, or particular implementations of the computer802and the described functionality. While memory506is illustrated as an integral component of the computer802, in alternative implementations, memory806can be external to the computer802. The application807is an algorithmic software engine providing functionality according to particular needs, desires, or particular implementations of the computer802, particularly with respect to functionality described in this disclosure. For example, application807can serve as one or more components, modules, applications, etc. Further, although illustrated as a single application807, the application807may be implemented as multiple applications807on the computer802. In addition, although illustrated as integral to the computer802, in alternative implementations, the application807can be external to the computer802. There may be any number of computers802associated with, or external to, a computer system containing computer802, each computer802communicating over network830. Further, the term “client,” “user,” and other appropriate terminology may be used interchangeably as appropriate without departing from the scope of this disclosure. Moreover, this disclosure contemplates that many users may use one computer802, or that one user may use multiple computers802. In some embodiments, the computer802is implemented as part of a cloud computing system. For example, a cloud computing system may include one or more remote servers along with various other cloud components, such as cloud storage units and edge servers. In particular, a cloud computing system may perform one or more computing operations without direct active management by a user device or local computer system. As such, a cloud computing system may have different functions distributed over multiple locations from a central server, which may be performed using one or more Internet connections. More specifically, cloud computing system may operate according to one or more service models, such as infrastructure as a service (IaaS), platform as a service (PaaS), software as a service (SaaS), mobile “backend” as a service (MBaaS), serverless computing, artificial intelligence (AI) as a service (AIaaS), and/or function as a service (FaaS). While the method and apparatus have been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope as disclosed herein. Accordingly, the scope should be limited only by the attached claims. | 50,112 |
11859450 | In Figure:1-central rod,11-rear section of central rod,12-front section of central rod,121-cooling fluid outlet,2-outer barrel,21-safety gear,211-clamping part,212-pressing part,22-drill bit,221-blade,3-integrity-preserving compartment,41-driving fluid channel,411-driving section,412-driving fluid outlet,42-cooling fluid channel,421-front opening of cooling fluid channel,431-fluid channel A,432-fluid channel B,433-fluid channel C,434-fluid channel D,435-fluid channel E,436-fluid channel F,437-fluid channel G,51-locking rod,511-connecting section,5111-start shear pin groove,512-outflow section A,5121-outflow hole A,513-sealing section B,514-inflow section A,5141-inflow hole,52-lock body,521-locking section,5211-start shear pin hole,522-sealing section A,523-fluid channel section,53-start shear pin,54-lock nut,541-fixing section,542-threaded section,55-sealing steel ring,56-fixing screw,61-valve housing,611-sealing section C,612-diversion section,613-locking section A,6131-locking groove A,62-lock housing,621-inflow section B,622-outflow section B,6221-outflow hole B,623-locking section B,6231-locking hole A,6232-locking hole B,63-locking sleeve,631-impacting section,632-locking section C,6321-locking groove B,6322-locking groove C,64-locking Ball,65-fixing ring,66-limit end,661-locking groove D,662-cooling fluid inlet,67-clamping ring,71-lock pin,72-connecting pipe,721-pressure relief section,7211-pressure relief hole,722-blocking section,73-shearing plunger,731-shearing section,732-recoil section,74-end shear pin. Examples In order to make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be further illustrated hereinafter by combing with the attached Figures. As shown inFIG.1, the drilling fluid channel structure of a core drilling rig, disclosed in the present invention, comprises a fluid channel activation module, a pressure relief module, a flow diverging and blocking module, a driving fluid channel41, a cooling fluid channel42, and a central rod1. The fluid channel activation module, the pressure relief module, and the flow diverging and blocking module are connected sequentially from the rear to the front. The central rod1passes through the fluid channel activation module, the pressure relief module, and the flow diverging and blocking module. The central rod1comprises the front section12and the rear section11. The driving fluid channel41and the cooling fluid channel42are connected at the rear side thereof to the flow diverging and blocking module. The driving fluid channel41comprises a driving section411, which is located between a stator and a rotor of a driving motor. The driving fluid channel41is provided with a driving fluid outlet412, which is in front of the driving section411. The driving fluid channel41is narrowed at the driving fluid outlet412, which faces the radial direction and is behind the integrity-preserving compartment3. The cooling fluid channel42passes through a layer disposed between an integrity-preserving compartment3and an outer barrel2. The front end of the outer barrel2is connected to a drill bit22, and a front end opening421of the cooling fluid channel is located at the side wall blade of the drill bit22. As shown inFIGS.2and3, the fluid channel activation module comprises a lock body52, a locking rod51, and a start shear pin53. Lock body52penetrates back and forth. The locking rod51and the lock body52are connected by the start shear pin53. From back to front, the lock body52comprises the locking section521, the sealing section A522, and the fluid channel section523. The outer wall of the locking section521has a start shear pin hole5211, which is a through hole, and the length of starting shear pin53is longer than the depth of the start shear pin hole5211. The locking rod51penetrates back and forth, and the locking rod51is in the lock body52. The locking rod51comprises a connecting section511, an outflow section A512, a sealing section B513, and an inflow section A514from back to front. The connecting section511is threadedly connected with the outflow section A512, and the sealing section B513and the inflow section A514are welded. The outer wall of the connecting section511is provided with a start shear pin groove5111, which is an annular groove. The start shear pin53is in the start shear pin hole5211and the start shear pin groove5111. The inner diameter of the locking section521is greater than the inner diameter of the sealing section A522. The outer wall of the connecting section511is provided with steps, whose outer diameter is greater than the inner diameter of the sealing section A522. The outer diameter of the connecting section511in front of the step is equal to the inner diameter of the sealing section A522. The starting shear pin groove5111is located on the outer wall of the step. The rear section11of the central rod is inside the locking rod51. The inner diameter of the fluid channel section523is greater than the outer diameter of the locking rod51. The inner diameter of the connecting section511, the outflow section A512, and the inflow section A513is greater than the outer diameter of the rear section11of the central rod. The sealing section B513is in a sealing fit with the rear section11of the central rod. There is a fluid channel A431between the rear section11of the central rod and the locking rod51, and the fluid channel A431is behind the sealing section B511. The back of the liquid channel A431is opened at the rear end of the locking rod51. The side wall of the outflow section A512is provided with an outflow hole A5121. The outflow hole A5121is behind the sealing section B513. The outflow hole A5121is inclined forward from the inside to the outside. There are multiple outflow holes A5121, and these holes A5121are evenly distributed along the circumference at the same axial position. The outflow holes A5121are connected to the fluid channel A431. The sealing section A522and the sealing section B513are in a sealing fit. There is a fluid channel B432between the lock body52and the locking rod51, which is in front of the sealing section A522. The axial distance from the front end of the sealing section A522to the rear end of the lock body52is less than the axial distance from the front end of the sealing section B513to the rear end of the lock body52. The start shear pin53passes through the start shear pin hole5211and is inserted into the start shear pin groove5111. The axial distance from the outer wall opening of the outflow hole A5121to the rear end of the lock body52is less than the axial distance from the rear end of the fluid channel section523to the rear end of the lock body52. A lock nut54and a sealing steel ring55are also comprised. The sealing steel ring55is connected to the lock body52. The inner wall of the rear section of the sealing steel ring55is in contact with the outer wall of the lock body52. The inner diameter of the rear section of the sealing steel ring55is shorter than the outer diameter of the lock body52in front of it. The inner diameter of the front section of the sealing steel ring55gradually increases from back to front, and the angle between the inner wall of the front section of the sealing steel ring55and the radial section are 45°. The lock nut54is behind the sealing steel ring55, and the lock nut54compresses the sealing steel ring55. The lock nut54penetrates back and forth, and the rear section11of the central rod passes through the inner cavity of the lock nut54. The front end of the lock nut54is threadedly connected to the rear end of the lock body52, and the start shear pin hole5211is opened at the rear thread of the lock body52, and the radial distance from the inner wall of the lock nut54to the bottom of the start shear pin groove5111is not less than the length of the start shear pin53. The lock nut54includes a fixing section541and a threaded section542. The outer diameter of the connecting section511behind the step is shorter than the inner diameter of the fixing section541, and smaller than the outer diameter of the step. The inner diameter of the threaded section542is equal to the outer diameter of the locking section521. The lock nut54has a fixing hole A in the axial direction, which is a through hole. The lock body52has a fixing hole B on the rear face, which is a blind hole. The fixing hole A and the fixing hole B are matched. The fixing screw56is also included, and the length of the fixing screw56is greater than the depth of the fixing hole A. The fixing screw56is in the fixing hole A, and the front end of the fixing screw56passes the fixing hole A, and is inserted into the fixing hole B. After the fluid is supplied, the locking rod51moves forward, the start shear pin53is cut, the start shear pin head is in the start shear pin hole5211, and the start shear pin tail5111is in the start shear pin groove. The start shear pin ends include a big end and a small end. The big end faces outwards, and the outer diameter of the big end is greater than the outer diameter of the small end. The start shear pin hole5211includes an outer section and an inner section, and the bore diameter of the outer section is not less than the outer diameter of the big end of the start shear pin, while the bore diameter of the inner section is not less than the outer diameter of the small end of the start shear pin. The bore diameter of the inner section is less than the outer diameter of the big end, and the depth of the outer section is not less than the length of the big end. The length sum of the small end and the start shear pin tail is greater than the depth of the inner section. Before the start shear pin53is cut, the outlet of the outflow hole A5121is at the sealing section A522, and the front end of the fluid channel A431is sealed. After the start shear pin53is cut, the locking rod51moves forward, the outlet of the outflow hole A5121is in front of the sealing section A522, and the fluid channel A431is connected to the fluid channel B432through the outflow hole A5121. As shown inFIGS.4and5, the flow diverging and blocking module comprises a valve housing61, a lock housing62, the locking sleeve63, and the fixing ring65. The central rod1, the valve housing61, the lock housing62, the locking sleeve63, the fixing ring65, and the outer barrel2are coaxial. The rear section11of the central rod passes through the inner cavity of the valve housing61, and the valve housing61is in the lock housing62. The lock housing62passes through the inner cavity of the locking sleeve63, and the valve housing61comprises a sealing section C611, a diversion section612and a locking section A613from back to front. The outer wall of the locking section A613is provided with a locking groove A613A6131, which is an annular groove. The lock housing62includes an inflow section B621, an outflow section B622and a locking section B623from back to front. The inner diameter of the inflow section B621is greater than the outer diameter of the sealing section C611, while the outer diameter of the sealing section C611is greater than the outer diameter of the diversion section612. The inner diameter of the outflow section B622is equal to the outer diameter of the sealing section C611. There is a fluid channel D434between the central rod rear section11and the inflow section B621, and there is a fluid channel E435between the outer wall of the central rod rear section11and the inner wall of the valve housing61. The rear end of the fluid channel D434is connected to the fluid channel B432, the fluid channel E435is connected to the fluid channel D434, and the fluid channel E435is connected to the cooling fluid channel42. The outflow section B622is provided with an outflow hole B6221, and the outflow hole B6221is connected to the driving fluid channel41. The width of the fluid channel E435is shorter than the width of the outflow hole B6221, the width of the fluid channel E435is shorter than the width of the driving fluid channel41. The locking section B623has a locking hole A6231and a locking hole B6232. The locking hole B6232is in front of the locking hole A6231. The outflow hole B6221, the locking hole A6231, and the locking hole B6232are all through holes with the same size. There is a locking ball64in both the locking hole A6231and the locking hole B6232. The diameter of the locking ball64is greater than the depth of the locking hole A6231. The locking sleeve63includes an impact section631and a locking section C632from back to front. The inner wall of the locking section C632has a locking groove B6321and a locking groove C6322, and both grooves are annular and have the same size. The locking groove C6322is in front of the locking groove B6321, and the distance between the locking groove B6321and the locking groove C6322is equal to the distance between the locking hole A6231and the locking hole B6232. The distance from the bottom of the locking groove A6131to the inner wall of the locking section B623is less than the diameter of the locking ball64, while the distance from the bottom of the locking groove A6131to the outer wall of the locking section B623is not less than the diameter of the locking ball64. The distance from the bottom of the locking groove B6321and the locking groove C6322to the outer wall of the locking section B623is less than the diameter of the locking ball64, while the distance from the bottom of the locking groove B6321and the locking groove C6322to the inner wall of the locking section B623is not less than the diameter of the locking ball64. The fixing ring65is fixed on the outer wall of the locking section B623, and the fixing ring65is behind the locking hole A6231. The inner diameter of the impact section631is greater than the outer diameter of the fixing ring65. The locking section C632is in front of the fixing ring65. The inner diameter of the outer barrel2is greater than the outer diameter of the lock housing62and the locking sleeve63. A safety gear21is connected to the inner wall of the outer barrel2, and the safety gear21includes a clamping part211and a pressing part212from back to front. The inner diameter of the front end of the pressing part212is shorter than the outer diameter of the impact section631. The inner diameter of the pressing part212is not less than the outer diameter of the fixing ring65. The inner diameter of the front end of the clamping part211is less than the outer diameter of the rear end of the fixing ring65, and the front end of the central rod rear section11is connected to a limit end66, which is in the locking section B623and in front of the locking section A613. The outer wall of the limit end66is provided with a locking groove D661, which is an annular groove. The locking groove D661is in front of the locking groove A613A6131. The gap between the outer wall of the limit end66and the inner wall of the lock housing62is less than the thickness of the front end of the locking section A613, and the axial distance from the front end of the clamping part211to the front end of the pressing part212is equal to the axial distance from the hole center of the locking hole A6231to the center of the locking groove B6321before stopping the drilling. The distance from the rear end of the sealing section C611to the rear end of the outflow hole B6221before stop of the drilling is greater than the axial distance from the hole center of the locking hole A6231to the center of the locking groove A613A6131after stop of the drilling. The axial distance from the hole center of the lock hole A6231to the center of the lock groove A613A6131after stopping the drilling is greater than the distance from the front end of the sealing section C611to the front end of the outflow hole B6221before stopping the drilling. The lock housing62and the valve housing61are locked or unconstrained by the locking ball64in the locking hole A6231, while the lock housing62and the locking sleeve63are locked or unconstrained by the locking ball64in the locking hole A6231. The lock housing62and the central rod1are locked or released by the locking ball64in the locking hole B6232. A snap ring67is also included. The outer diameter of the snap ring67is longer than the inner diameter of the fixing ring65, and the inner diameter of the snap ring67is shorter than the inner diameter of the fixing ring65. The snap ring67is inserted into the groove of the outer wall of the locking section B623. The fixing ring65is snapped between the rear end of the snap ring67and the front end of the outflow section B622. The front end of the locking section C632is supported by a spring. Before stop of the drilling, the lock housing62is locked with the valve housing61, the front end of the sealing section C611is at the inflow section B621, and the fluid channel D434is connected to the outflow hole B6221. The motor rotates, the outer barrel2has a built-in safety gear21, and the outer barrel2moves forward to the limit position. The outer barrel2drives the safety gear21to hit the locking sleeve63, so that the locking ball64in the locking hole A6231is moved outward, and the restriction on the valve housing61is released. The valve housing61moves forward, the sealing section C611and the outflow section B621are in a sealing fit, and the fluid channel D434is separated from the outflow hole B6221. Thus, the driving fluid channel is closed, and the drilling is stopped. At this time, the locking groove D661, the locking hole B6232and the locking groove C6321are directly opposite. The locking ball64in the locking hole B6232moves outwards, and the constraint on the central rod1is released. As shown inFIGS.6to8, the front end of the limit end66is connected to the front section12of the central rod. There is a fluid channel F436in the axial direction inside the front section12of the central rod. The limit end66is provided with a cooling fluid inlet662. The fluid channel E435is connected to the fluid channel F436through the cooling fluid inlet662. The front end of the central rod front section12is sealed, which is connected to the integrity-preserving compartment3. The central rod front section12and the integrity-preserving compartment3are both in the outer barrel2, and the front side wall of the central rod front section12is provided with a cooling fluid outlet121. There is a fluid channel G437in the interlayer between the integrity-preserving compartment3and the outer barrel2. The fluid channel G437is connected to the fluid channel F436through the cooling fluid outlet121. The cooling fluid channel42includes the fluid channel F436, the fluid channel G437, the cooling fluid inlet662, and the cooling fluid outlet121. The side wall of the drill bit22is provided with a front end opening421of the cooling fluid channel, and the blade221of the drill bit22passes through the front end opening421, which is in communication with the fluid channel G437. As shown inFIGS.9and10, the pressure relief module comprises a connecting pipe72and a lock pin71. The front end of the connecting pipe72is connected to the lock housing62, while the rear end of the connecting pipe72is connected to the lock body52. The rear end of the lock pin71is connected to the locking rod51. The rear section11of the central rod penetrates the inner cavity of the lock pin71, which is in the connecting pipe72, and there is a fluid channel C433between the rear section11of the central rod and the lock pin71and the locking rod51. The side wall of the locking rod51is provided with an inflow hole5141, which is in the inflow section A514. There are multiple inflow holes5141, which are distributed back and forth on different sides. The fluid channel B432and the fluid channel C433are connected through the inflow hole5141, and the fluid channel C433is connected to the fluid channel D434. The connecting pipe72comprises a pressure relief section721and a flow blocking section722from back to front. The lock pin51is in a sealing fit with the blocking section722, whose inner diameter is shorter than the inner diameter of the pressure relief section721. There is a pressure relief hole7211at the pressure relief section721, and the pressure relief hole7211is a through hole. There is a shearing plunger in the fluid channel B432. The inner diameter of the shearing plunger73is longer than the outer diameter of the lock pin71and the locking rod51, and the shearing plunger73is connected to the lock body52through the end shearing pin74. The shearing plunger73includes a shearing section731and a recoil section732from back to front. The outer wall of the shearing section731and the inner wall of the lock body52are in a sealing fit. The outer diameter of the recoil section732is equal to the inner diameter of the front part of the pressure relief hole7211in the pressure relief section721. Before stop of the drilling, the front end of the recoil section732is in front of the front end of the pressure relief hole7211, and the recoil section732and the part of the pressure relief section721in front of the pressure relief hole7211are in a sealing fit. After stop of the drilling, the front fluid flows back and impacts the front end of the shearing plunger73, and the shearing plunger73moves back. The front end of the recoil section732is behind the front end of the pressure relief hole7211, and the fluid channel B432is connected to the pressure relief hole7211, and the returning driving fluid is discharged from the pressure relief hole7211. Of course, there still may be many other examples of the present invention. Without departing from the spirit and the essence of the present invention, those skilled in the art can make various corresponding changes and deformations according to the invention, but these corresponding changes and deformations shall belong to the protection scope of the claims of the present invention. | 21,910 |
11859451 | DETAILED DESCRIPTION Disclosed are depth of cut control (DOCC) assemblies for a drill bit that have moveable DOCC elements to change their exposure and the corresponding engagement of cutters during drilling. Changing the engagement of the DOCC elements may change the bit aggressiveness. For example, it may be desirable to have a less aggressive bit in some applications where there is more need for directional control or that otherwise may entail slower drilling, and then transition to a more aggressive bit by backing off the DOCC elements where more weight on bit is used to drill faster. Rather than moving back and forth between exposure positions, the DOCC elements in at least some embodiments are activated or deactivated once during drilling. This serves various drilling applications for which it is desirable for cutters to have one depth of engagement during part of the drill bit run, and another depth of engagement in a subsequent part of the drill bit run. For example, in forming a multilateral wellbore, DOCC elements may be set with a higher initial exposure (relative to the cutter profile) for curve runs to prevent the bit from over-engaging, but transition to a lower exposure once in the lateral wellbore, so as not limit rate of penetration (ROP). Such one-time activation or de-activation and one-way change in exposure height may reduce costs and increase reliability. Numerous example embodiments are given that provide one-way movement of DOCC elements from a first exposure position to a second exposure position. The examples discussed primarily use rolling DOCC elements, but non-rolling DOCC elements may also be used. One or more embodiments include a DOCC element rotatably positioned in a retainer pocket along the blade to limit a depth of cut of one of the fixed cutters. A retention member initially retains the DOCC element within the retainer pocket at a first exposure position. The retention member is configured to release the DOCC element downhole to allow one-way movement of the DOCC element to a second exposure position. The retention member may comprise, in some examples, one or more burst discs, pins, shelves, bearing elements, or caps that initially retain the DOCC element in the first exposure position. The retainer elements may be configured to yield, fail, displace, and/or disintegrate, such as by melting, liquifying, dissolving, abrading, or wearing, in response to a threshold force, pressure, or temperature, or contact with a solvent or abrasive fluid, as non-limiting examples. The retainer elements may also comprise a plurality of retainer elements corresponding to different exposure positions so that the DOCC element may successively move from one exposure position to the next during drilling. These and other examples are further understood with respect to the figures discussed below. FIG.1is an elevation view of an example drilling system10in which a drill bit40according to aspects of this disclosure may be used to drill a wellbore14. Drilling system10may be assembled at a well site with drilling equipment such as a rotary table, drilling fluid pumps and drilling fluid tanks at an above ground location (i.e., at the surface)12. For example, a drilling rig16may be provided with various features associated with terrestrial drilling operations with a land drilling rig. However, teachings of the present disclosure may be applied in offshore drilling operations, e.g., operations with drilling equipment located on offshore platforms, drill ships, semi-submersibles and drilling barges. The drilling system10includes a drill string20including a bottom hole assembly (BHA)22with the drill bit40secured at a lower end for forming a wellbore14in an earthen formation15below the surface12. The wellbore14may follow any given wellbore path to reach one or more target zones in the formation15. The wellbore14in this example happens to be a multilateral wellbore that includes a generally vertical main bore14aand at least one wellbore branch14bthat deviates from vertical. The wellbore branch14bmay be formed, for example, using a whipstock assembly at a multilateral junction18. Various directional drilling techniques may also be used to control the direction of drilling of the wellbore(s) in an effort to reach one or more target zones. The BHA22may include the drill bit40and any number of other BHA components, schematically depicted at22a,22band22c, coupled to the drill string20above the drill bit40. The BHA components22a,22band22cmay include, but are not limited to, drill collars, rotary steering tools, directional drilling tools, downhole drilling motors, reamers, hole enlargers, stabilizers etc. The number and types of BHA components22a,22band22cmay depend on anticipated downhole drilling conditions and the type of wellbore14that will be formed by drill string20and rotary drill bit40. The BHA22may also include various types of well logging tools (not expressly shown) and other downhole tools associated with directional drilling of a wellbore. Examples of logging tools and/or directional drilling tools may include, but are not limited to, acoustic, neutron, gamma ray, density, photoelectric, nuclear magnetic resonance, rotary steering tools and/or any other commercially available well tool. The BHA components22a,22band22cmay also include a downhole motor capable of rotating the drill bit40with respect to an upper portion of the drill string20. The wellbore14may be drilled by engaging the drill bit40with the formation while rotating the drill bit40, such as by rotating the entire drill string20from the surface and/or by rotating the drill bit40with the mud motor. The wellbore14may be defined in part by a casing string24that may be cemented in place, extending along at least a portion of the wellbore14. Portions of the wellbore14that do not include casing string24may be described as “open hole.” Various types of drilling fluid, or “mud,” may be pumped from the surface12through drill string20. The drilling fluid may be expelled from the drill string20through nozzles passing through the drill bit40. The drilling fluid may be circulated back to surface12through an annulus26defined between an outside diameter of the drill string20and a surrounding structure. Along an open hole portion, the annulus26is defined between the drill string20and an inside diameter of the wellbore14a. The inside diameter may be referred to as the sidewall of the wellbore14a. Along a cased portion, the annulus26may be defined between the drill string20and an inside diameter of the casing string24. The drill bit40may rotate with respect to a bit rotational axis44in a direction defined by directional arrow45. As the drill bit40is rotated, the cutters, which may include fixed cutters and/or rolling cutters, may engage and cut the formation. As discussed below, a plurality of DOCC elements may be provided on the drill bit40to limit the engagement of the cutters. The cutters may cut by scraping, gouging, shearing, or otherwise disintegrating the formations surrounding wellbores14. The resulting cuttings may be continuously removed by the drilling fluid circulated through the drill string20back to the surface12, where the cuttings may be removed from the drilling fluid by surface equipment. FIG.2is an isometric view of a drill bit100in accordance with aspects of the present disclosure, as an example configuration of the drill bit40generally depicted inFIG.1. The drill bit100includes a bit body102, which may be formed, for example, from a steel or a metal matrix composite. The bit body102includes radially and longitudinally extending blades104. Junk slots112are defined between adjacent blades104. A plurality of nozzles or ports114can be arranged within junk slots112for ejecting drilling fluid that cools drill bit100and otherwise flushes away cuttings and debris generated while drilling. When incorporated into a drill string (e.g.,FIG.1), the bit body102generally rotates about a longitudinal drill bit axis107with leading faces106of the blades104facing the direction of rotation. The drill bit100may be categorized as a fixed cutter drill bit, in that its cutting structure comprises a plurality of cutters116secured at fixed cutting orientations to drill into the earthen formation under an applied weight-on-bit (WOB). The plurality of fixed cutters116may be secured to the blades104within corresponding cutter pockets sized and shaped to receive the fixed cutters116. Each cutter116, in this example, comprises a fixed cutter secured within its corresponding cutter pocket via brazing, threading, shrink-fitting, press-fitting, snap rings, or any combination thereof. The fixed cutting orientation at which the fixed cutters116are held in blades104and respective cutter pockets may comprise predetermined angular orientations and radial locations, and may present the fixed cutters116with a desired back rake angle against the formation being drilled. As the drill bit100is rotated on the drill string about the bit axis107, the fixed cutters116sweep three dimensional (3D) cutting profiles. During drilling, the fixed cutters116are driven through the rock by the combined forces of the weight-on-bit and the torque applied to the drill bit100. During drilling, the fixed cutters116may experience a variety of forces, such as drag forces, axial forces, reactive moment forces, or the like, due to the interaction with the underlying formation being drilled as drill bit100rotates. Each fixed cutter116may include a generally cylindrical substrate made of a hard material, such as tungsten carbide (WC), and a cutting element secured to the substrate. The working surface of the cutting element is typically flat or planar, but may also exhibit a curved or otherwise non-planar exposed surface that defines a cutting edge oriented for cutting into an earthen formation. The cutting element may include one or more layers of an ultra-hard material, such as polycrystalline diamond (PCD), polycrystalline cubic boron nitride, impregnated diamond, etc., which generally forms a cutting edge and the working surface for each fixed cutter116. In some cases, a PCD cutting element may be formed and bonded together with the substrate in a high-temperature, high-pressure press cycle, with the resulting cutter referred to as a polycrystalline diamond compact (PDC). When using polycrystalline diamond as the ultra-hard material, fixed cutter116may be referred to as a polycrystalline diamond compact cutter or PDC cutter, and drill bits made using such PDC fixed cutters116are generally known as PDC bits. The drill bit100also has rolling element assemblies118a,118bsecured to the bit body102. The orientation of a rolling element in each rolling element assembly118a,118bdetermines, at least in part, whether the rolling element operates as a cutter, a rolling depth of cut control (DOCC) element, or a hybrid of both. In this example the rolling cutter assemblies118aare configured as rolling cutters and the rolling cutter assemblies118bare configured as rolling depth of cut controllers (rolling DOCC). The rolling cutters118ainclude rolling elements that, like the fixed cutters116, have cutting edges oriented for cutting into an earthen formation while drilling. In the design of the drill bit100, the desired back rake and side rake angles may be selected and otherwise optimized with respect to fixed cutters116and/or rolling cutters118a. The rolling depth of cut controllers118binclude rolling DOCC elements positioned to instead roll against the formation, limiting a depth of cut of one or more of the fixed cutters116and/or rolling cutters118a. Rolling DOCC elements may prove advantageous in allowing for additional weight-on-bit to enhance directional drilling applications without over engagement of the fixed cutters116. Effective depth of cut control also limits fluctuations in torque and minimizes stick-slip, which can cause damage to fixed cutters116. At least some of the rolling element assemblies118a,118bhave rolling elements whose exposure positions (e.g., exposure height of a rolling element relative to the cutting profiles of adjacent cutters whose depth is limited thereby) may change during drilling, which may change how aggressively the drill bit100drills. Those rolling elements are initially retained at a first exposure position, such as while drilling a first portion of the wellbore, and then released downhole to allow movement of the DOCC element to a second exposure position. The movement from the first exposure position to the second exposure position may be one-way, so that at some point during drilling the drill bit may become more aggressive or the drill bit may become less aggressive. For example, the DOCC elements may initially be set with a higher exposure (i.e., greater engagement) for curve applications to prevent the cutters from over-engaging, but transition to a lower exposure in a lateral wellbore so as not limit rate of penetration (ROP). Several example configurations are discussed below and conceptually illustrated in subsequent figures that enable this one-way movement from a first exposure position to a second exposure position. In some examples, the DOCC elements move inwardly to achieve a one-time deactivation, thereby providing a less aggressive, shallower initial depth of cut that subsequently increases for more aggressive drilling. In other examples, the DOCC elements may instead be configured to move outwardly for a one-time activation during drilling, thereby providing a more aggressive drilling initially, followed by a shallower depth of cut later in the drilling. FIG.3is an enlarged portion of one of the blades104indicated by the dashed box shown inFIG.2, including one example of a rolling cutter118aand one example of a rolling DOCC118b. Each rolling element assembly118a,118bincludes a rolling element122rotatably secured on the blade104. Exposed portions of the rolling elements122are illustrated in solid linetype, while portions of rolling elements122that are seated within corresponding retainer pockets illustrated in dashed linetype. The pockets may be defined by the blade104itself or by a retainer housing embedded in the blade104. Each rolling element122has a rotational axis A, a Z-axis that is perpendicular to the blade profile, and a Y-axis that is orthogonal to both the rotational and Z-axes. As shown, the exposed portion of each rolling element122may be constant with respect to the position along the rotational axis A of the rolling element, in either the DOCC or the cutter orientation. A rolling element may be considered a rolling cutter or a rolling DOCC element depending on its position and orientation. If, for example, the rotational axis A of a rolling element122is substantially parallel to a tangent to outer surface119of the blade profile, that rolling element assembly118bmay generally operate as a rolling DOCC element. For example, if the rotational axis A of the rolling element122passes through or lies on a plane that passes through the longitudinal bit axis107(FIG.2) of the drill bit100(FIG.2), then the rolling element assembly118bmay substantially operate as a rolling DOCC element. If, however, the rotational axis A of a rolling element122is substantially perpendicular to leading face106of the blade104, then that rolling element assembly118amay substantially operate as a rolling cutting element. For example, if the rotational axis A of a rolling element122is perpendicular to or lies on a plane that is perpendicular to a plane passing through the longitudinal axis107(FIG.2) of the drill bit100(FIG.2), then the rolling element assembly118amay substantially operate as a rolling cutting element. Another design consideration is the placement of the rolling element assemblies118a,118brelative to the fixed cutters116. In this example, the fixed cutters116form part of a primary cutting structure115, and the rolling cutter118ais positioned on the blade104as a backup or secondary cutter to the fixed cutter116amost directly ahead of the rolling cutter118, towards the leading face106of the same blade104. Although not required, the rolling cutter118amay be positioned directly behind the primary cutter116a. Alternatively, the rolling cutter118amay be staggered laterally (in the Y direction) with respect to that primary cutter116aso their respective cutting profiles only partially overlap. As another example, the placement of the rolling cutter118aon the blade104may instead be selected relative to the cutter on another blade (not shown), such as to align the path of the rolling cutter118abehind the path of the cutter on the other blade as they rotate about the bit axis. Placement of the rolling DOCC118bmay be selected to limit the depth of cut of one or more of the fixed cutters116. Typically, the rolling DOCC118bwould limit the depth of cut of an adjacent or nearest fixed cutter, and typically (although not necessarily) on the same blade104. Although the rolling DOCC118bcould at least indirectly affect the depth of cut of other cutters, other fixed or rolling DOCCs could be positioned nearer to such other cutters to more directly affect their respective depth of cut. In this example, the rolling DOCC118bis placed to limit the depth of cut of the fixed cutter116bmost directly ahead of the rolling DOCC118b. FIG.4is a portion of the blade104according to another example configuration wherein rolling cutters118aand fixed cutters116are both included as part of the primary cutting structure. Other elements such as one or more fixed cutters, rolling cutters, and/or DOCC elements may be positioned in a secondary structure117such as at locations indicated by circles in dashed linetype. The rolling cutters118amay be initially retained at a first exposure position and released downhole to a second exposure position (e.g., in a direction perpendicular to the page). The first exposure position of the rolling cutters118amay be, for example, at substantially the same height as the fixed cutters116. The second exposure position may be below the first exposure position (i.e., moved into the page). In that way, the rolling cutters118amay initially be positioned to cut earthen formation with about the same exposure to the earthen formation as the fixed cutters116during drilling of a first wellbore portion. Then, the rolling cutters118amay drop down for drilling a second wellbore portion. The rolling cutters118a, which functioned as rolling cutters in the first exposure position may function at least partially as DOCC elements to the fixed cutters116in the second exposure position. That is, when the fixed cutters116engage the formation with sufficient depth that the rolling cutters118aalso engage the formation, contact of the rolling cutters118awith the formation may resist further depth of engagement by the fixed cutters116. The followingFIGS.5to21present a non-exhaustive number of examples of mechanical configurations of a depth of cut control (DOCC) element initially retained at a first exposure position that may be released to allow one-way movement of the DOCC element to a second exposure position. The release of the DOCC element may result from a failure or yielding of a retention member, such as due to plastic deformation, shearing, melting, dissolution, or wear of the retention member as a result of some downhole event. The downhole event may include, for example, an increase in a force, a pressure, or a temperature above some threshold, contact by a fluid that dissolves the retention member (solvent) or flow of an abrasive fluid over the retention member (abrasion), or the erosion of the retention member by the rolling element. In any of these examples, unless otherwise noted, the rolling element assemblies may be configured as a rolling DOCC element, a rolling cutter, or some hybrid thereof, based on the orientation and/or positioning such as described in the foregoing figures. In each of these examples, the DOCC element is depicted as a rolling DOCC element, but could alternatively be substituted with a non-rolling element. In each of these examples, a rolling element pocket is defined by a retainer housing disposed on the blade, but the rolling element pocket could alternatively be defined by the blade itself (without a structurally separate housing). FIG.5is a rolling DOCC assembly130with the rolling element122initially retained in a first exposure position by a retention member comprising a rupture disc (i.e., burst disc)132. The rolling element122, in at least the first exposure position, limits a depth of cut of at least one fixed cutter116. The rolling element122is captured in a retainer housing124between a wall125and a floor126at least partially defining a retainer pocket127in which the rolling element122is captured. A top portion (i.e., cap)129of the housing may be positioned over the rolling element122during assembly to keep the rolling element secured in the blade104. In an alternative configuration, the wall125may be incorporated with the top portion (cap)129of the housing so the cap129including the wall125may be positioned over the rolling element122, in which case the wall125and the floor126may be structurally separate. In yet another embodiment, the rolling element122, housing124, and cap129may be pre-assembled as a housing assembly prior to installing the housing assembly on the blade104. (In other embodiments and figures, it will be understood that some version of the cap129may also be present even if not explicitly called out.) The retainer pocket127could alternatively be defined by the blade104itself, without including a distinct or structurally separate housing. The burst disc132is incorporated into the retainer housing124, beneath the rolling element122. This creates a gap between the burst disc132and the floor126of the retainer pocket127. The burst disc132is rated to rupture (i.e., burst) at a specified loading, such as if the weight on bit loading (FWOB) reaches a threshold. The rolling element122limits depth of cut of a fixed cutter116in the first exposure position illustrated inFIG.5. In the first exposure position, the top of the rolling element122sits slightly below the fixed cutter116. A depth of engagement “d” of the fixed cutter116is related to this height difference between the fixed cutter116and the rolling element122, where height may be as measured in the Z-direction with reference toFIG.3. The bursting of the burst disc132will release the rolling element122to allow one-way movement of the rolling element122further down into the pocket127to a second exposure position. This movement from the first exposure position to the second exposure position will increase the depth of engagement of the fixed cutters116, reducing or eliminating exposure of the rolling element122with the formation being drilled. This movement of the rolling element122from the first exposure position to the second exposure position upon bursting of the burst disc132is considered one-way, in that the rolling element122is not biased back toward the first exposure position while drilling. For so long as FWOBis applied, the rolling element122may remain at the floor126of the retainer housing124. If FWOBis released such as with WOB removed, it may be possible for the rolling element122to have some vertical play in the retainer cavity127, such as to wobble or move back up toward the first exposure position. However, some sort of intervention would be required, such as to restore or replace the burst disc with another burst disc or some other retention member, to retain the rolling element122back in the first exposure position. FIG.6is a another rolling DOCC assembly140with a plurality of spaced apart retention members each comprising a burst disc. By way of example, the plurality of burst discs include first, second, and third burst discs individually designated at132A,132B,132C, although a different number of burst discs could be included in other embodiments. A spacing between the burst discs132A,132B,132C is exaggerated for clarity in the figure, and could be spaced/positioned so the rolling element122still sticks out at least slightly after132A and132B have burst. The burst discs132A,132B,132C are vertically arranged one above the other, with a gap between adjacent burst discs132A/132B and132B/132C and between the third burst disc132C and the floor126. The rolling element122is initially retained in a first exposure position by the first burst disc132A. The burst disc132may be rated to burst at a specified loading, such as if the weight on bit loading (FWOB) reaches a first threshold. The rolling element may next be retained in a second exposure position by the second burst disc132B until the second rupture disc132B bursts, and then in a third exposure position by the third burst disc132C until the third burst disc132C bursts. The burst discs may be selected to have the desired burst rating for each. The burst ratings may be the same or different. In one example, each burst disc has the same burst rating, but fails at different (e.g., progressively larger) loading FWOBdue to the increased engagement of the fixed cutter116(and associated WOB required) at the successive exposure positions of the rolling element122. In another example, the burst ratings of the burst discs132A,132B,132C may be progressively larger. Each movement of the rolling element122from one exposure position to the next upon bursting of the respective burst disc may be one-way. For example, the rolling element122changes exposure position upon bursting of the first burst disc132A, again upon bursting of the second burst disc132B, and again upon bursting of the third burst disc132C. After each change in exposure position, the rolling element122is not biased back toward the previous exposure position in a way that would again reduce engagement of the fixed cutter116. Similarly, the overall movement from the first exposure position (all burst discs intact) to when the rolling element122bottoms out on the floor126(all burst discs failed) is also considered one-way. FIG.7is a rolling DOCC assembly150wherein the rolling element122is initially retained in the first exposure position by a retention member comprising a shelf152. The rolling element122, in at least the first exposure position, limits a depth of cut of at least one fixed cutter116. The shelf152may be incorporated into the retainer housing124beneath the rolling element122, creating a gap between the shelf152and the floor126. For example, the shelf152may be welded, brazed, or bonded to an interior of the retainer housing124. Alternatively, the retainer housing124and shelf152may be integrally formed, such as using additive manufacturing (i.e., 3D printing). The shelf152is configured to yield at a specified loading, such as if the weight on bit loading (FWOB) reaches a threshold. The shelf152in this configuration comprises a yield zone154contacted by the rolling element122. The yield zone154may comprise a tapered or otherwise thinned portion of the shelf152that is thinner than the shelf152is at the periphery where it is coupled to the retainer housing124. Thus, the yield zone154may preferentially yield while a periphery of the shelf152remains intact. The yield zone154may be sufficiently strong to retain the rolling element122in the first exposure position up until the specified loading, at which point the yield zone154may yield or otherwise fail, allowing the rolling element122to move down to the second exposure position. This movement may be one-way, as was described in reference to the prior embodiments ofFIGS.5and6. FIG.8is another rolling DOCC assembly160with a plurality of spaced apart shelves, similar in some respects to the spaced apart shelves ofFIG.6. By way of example, the plurality of shelves include first, second, and third shelves individually designated at154A,154B,154C, although a different number of shelves could be included in other embodiments. The shelves154A,154B,154C, similar to the burst discs ofFIG.6, are vertically arranged one above the other, with a gap between adjacent shelves154A/154B,154B/154C and between the third shelf154B and the floor126of the retainer housing124. The rolling element122is initially retained in a first exposure position by the first shelf154A. Each shelf may be rated to yield at a specified loading, such as if the weight on bit loading (FWOB) reaches a first threshold. The rolling element may next be retained in a second exposure position by the second shelf154B until the second shelf154B yields, and then in a third exposure position by the third shelf154C until the third shelf154C yields. The shelves may be selected to have the desired yield rating for each. The yield ratings may be the same or different. In one example, each shelf has the same yield rating, but fails at different (e.g., progressively larger) loading FWOBdue to the increased engagement of the fixed cutter116(and associated WOB required) at the successive exposure positions of the rolling element122. In another example, the yield ratings of the shelves152A,152B,152C may be progressively larger. As with the configuration ofFIG.6, the movement of the rolling element122inFIG.8from one exposure position to the next upon yielding of the respective shelf may be one-way. For example, the rolling element122changes exposure position upon yielding of the first shelf152A, again upon yielding of the second shelf152B, and again upon yielding of the third shelf152C. After each change in exposure position, the rolling element122is not biased back toward the previous exposure position in a way that would again reduce exposure of the fixed cutter116back to the prior exposure position, at least without intervention. Similarly, the overall movement from the first exposure position (all shelves intact) to when the rolling element122bottoms out on the floor126(all shelves failed) is also considered one-way. FIG.9is another rolling DOCC assembly170wherein the rolling element122is initially retained in the first exposure position by a retention member comprising a set of one or more shear pins172. The rolling element122, in at least the first exposure position, limits a depth of cut of at least one fixed cutter116. The shear pins172may be incorporated into the retainer housing124beneath the rolling element122, creating a gap between the shear pins172and the floor126. For example, the shear pins172may be welded, brazed, or bonded to an interior of the retainer housing124. Alternatively, the retainer housing124and shear pins172may be integrally formed, such as using additive manufacturing (i.e., 3D printing). The shear pins172may comprise one or more pairs of opposing shear pins, which may be at the same height relative to the floor126of the retainer housing124. The shear pins172may be spaced apart around a periphery of the retainer housing124to uniformly support the rolling element122. In the illustrated example, the rolling element122sits directly on the shear pins172, but alternatively, the retention member could comprise a shelf or other member supported by the shear pins172with the rolling element122contact the shelf or other member. The shear pins172are configured to fail, typically by shearing and/or yielding at a specified loading, such as if the weight on bit loading (FWOB) reaches a threshold. The shear pins172may be sufficiently strong to retain the rolling element122in the first exposure position up until the specified loading, at which point the shear pins172shear, yield, or otherwise fail, allowing the rolling element122to move down to the second exposure position. This movement may be one-way, as was described in reference to prior embodiments. FIG.10is another rolling DOCC assembly180with a plurality of spaced apart levels of shear pins, similar in some respects to the spaced apart burst discs ofFIG.6and spaced apart shelves ofFIG.8. By way of example, the plurality of levels of shear pins172include first, second, and third levels of shear pins individually designated at172A,172B,172C, although a different number of levels of shear pins could be included in other embodiments. The levels of shear pins172are vertically arranged one above the other, with a gap between adjacent levels of shear pins172A/172B,172B/172C and between the third level of shear pins172C and the floor126of the retainer housing124. The rolling element122is initially retained in a first exposure position by the first level of shear pins172A. The first level of shear pins172A may be rated to fail at a specified loading, such as if the weight on bit loading (FWOB) reaches a first threshold. The rolling element may next be retained in a second exposure position by the second level of shear pins172B until the second level of shear pins172B yields, and then in a third exposure position by the third level of shear pins172C until the third level of shear pins172C yields. The levels of shear pins may be selected to have the desired failure rating for each. The failure ratings may be the same or different. In one example, each level of shear pins has the same failure rating, but fails at different (e.g., progressively larger) loading FWOBdue to the increased engagement of the fixed cutter116(and associated WOB required) at the successive exposure positions of the rolling element122. In another example, the failure ratings of the levels of shear pins172A,172B,172C may be progressively larger. As with other configurations, the movement of the rolling element122inFIG.10from one exposure position to the next upon failure of the respective level of shear pins may be one-way. For example, the rolling element122changes exposure position upon failure of the first level of shear pins172A, again upon failure of the second level of shear pins172B, and again upon failure of the third level of shear pins172C. After each change in exposure position, the rolling element122is not biased back toward the previous exposure position in a way that would again reduce engagement of the fixed cutter116back to the prior exposure position, at least without intervention. Similarly, the overall movement from the first exposure position (all levels of shear pins intact) to when the rolling element122bottoms out on the floor126(all levels of shear pins failed) is also considered one-way. In another embodiment, a shape memory material could be used as a retainer element. Instead of failing or yielding like the burst discs, shelves, or pins, the shape memory material could change shape in response to a change in temperature. For example, a retainer element may be formed having an arched shape, similar to the example shape of burst discs above, except that the arched shape may increase with temperature. Even if the shape change is reversible by reducing temperature (e.g., when removing the drill bit from the well), the movement of the retainer element in response to temperature may still be considered one-way in the context of drilling, since temperature increases with depth. FIG.11is another rolling DOCC assembly190wherein the rolling element122is initially retained in the first exposure position by a retention member comprising a shape memory material member192. The rolling element122, in at least the first exposure position, limits a depth of cut of at least one fixed cutter116. The shape memory material member192may initially support the rolling element122at the first exposure position. The shape memory material member192comprises a shape memory material configured to change shape to release the DOCC element downhole in response to a temperature change. FIG.12is the rolling DOCC assembly190ofFIG.11after the shape memory material member192has changed shape in response to a temperature change downhole, thereby releasing the rolling element122from the first exposure position ofFIG.11to a second exposure position as shown inFIG.12. The second exposure position further exposes the fixed cutter116to the formation being cut. The movement from the first exposure position to second exposure position may be one-way (e.g., for one-time deactivation of the rolling element122) in that the shape memory material presumably remains in the changed shape state while it remains at or above the downhole temperature at which it changed shape. FIG.13is another rolling DOCC assembly200in which the rolling element122is supported on a retention member (e.g., a bearing)202formed of a disintegrating material. The retention member202may disintegrate such as by wearing, eroding, melting, dissolving, or a combination thereof. The rolling element122, in at least the first exposure position, limits a depth of cut of at least one fixed cutter116. The retention member202may be secured within the retainer housing124, such as by welding, brazing, or bonding, or it may be integrally formed with the retainer housing124. The rolling element122is typically made from a relatively hard and wear-resistant material, such as diamond or tungsten carbide. The retention member202could be made of a structural material with sufficient mechanical properties to initially retain the rolling element122in the first exposure position. The structural material of the retention member202may be softer or less wear-resistant than the rolling element122, so that the retention member202preferentially wears as the rolling element122rolls against the retention member202under a drilling load, or in response to an abrasive fluid, a melting temperature, a solvent, or other agent that will promote disintegration. As the retention member202disintegrates, the exposure of the roller is thereby reduced. Optionally, a wear-resistant (e.g., hardened) insert128could be disposed on the floor126of the retainer housing124and/or the retainer housing124or at least the floor126of the retainer housing124could be formed of a wear-resistant material. FIG.14is the rolling DOCC assembly200ofFIG.13after the retention member202has worn down or otherwise disintegrated, gradually allowing the rolling element122to move from the first exposure position ofFIG.13to a second exposure position ofFIG.14. The wearable portion of the retention member202may be specifically configured with a wear or disintegration rate selected to allow the drill bit to drill to a target depth. For example, the target depth may be at least approximately the depth from surface to the start of a lateral wellbore, at which point an increased engagement is desired for the fixed cutters116. The optional hardened insert128or the hardened floor126may resist further wear so that the rolling element122is retained in the second exposure position with continued drilling after the rolling element122has reached the second exposure position ofFIG.14. FIG.15is another rolling DOCC assembly210with a retention member comprising a bearing element212with variable wear (or other variable disintegrating) properties. The rolling element122, in at least the first exposure position, limits a depth of cut of at least one fixed cutter116. By way of example, the bearing element212includes a relatively hard upper layer212A and a relatively soft (or otherwise more easily disintegrated) lower layer212B. The wear/disintegration rate of the upper layer212A by contact with the rolling element122is therefore reduced as compared with the lower layer212B under the same loading conditions. The rolling element122is therefore supported by the upper layer212A with relatively low rate of change in exposure height over a specified drilling depth. The upper layer212A may be configured, such as by selection of material and thickness, to withstand a certain initial depth of drilling a wellbore. FIG.16is the rolling DOCC assembly210ofFIG.15after the rolling element122has worn through the upper layer212A of the bearing element212and has made initial contact with the lower layer212B. FIG.17is the rolling DOCC assembly210ofFIGS.15and16after the rolling element122has worn most of the way through the lower layer212B of the bearing element212. The rate of change in exposure height of the rolling element fromFIG.16toFIG.17per foot of drilling depth is greater in this example than the rate of change in exposure height of the rolling element fromFIG.15toFIG.16. However, the bearing element212could alternatively be configured so that the wear rate decreases over the course of drilling to a certain depth. In other embodiments, rather than discrete layers of different hardness, the bearing element212could be formed of a hardness gradient that varies with depth. Such other bearing element configurations could be formed, for example, using additive manufacturing, such as by varying the material and/or material density with thickness of the bearing element. FIG.18is another rolling DOCC assembly220with a retainer element222that initially surrounds the rolling element122. The rolling element122, in at least the first exposure position, limits a depth of cut of at least one fixed cutter116. The retainer element222may also functionally serve as the housing, and may comprise a2(or more) housing portions222A,222B that may be fixed together about the rolling element122. In this example, the housing portions222A,222B are horizontally arranged on either side of the rolling element122. Alternative arrangements (e.g. vertically arranged, upper/lower housing portions) are also within the scope of this disclosure. The rolling element122could alternatively be embedded in the retainer element222in any other suitable way during manufacturing. FIG.19is the rolling DOCC assembly220ofFIG.18, wherein the retainer element222has partially worn away in response to rolling contact by the rolling element122. The retainer element222may wear not only with depth but also laterally, as illustrated. The retainer element222(and retainer housing, if included) may allow lateral wearing of the retainer element222. Any materials that are disintegrated while drilling may be circulated to surface with other cuttings. A variety of materials may be selected for retention members designed to wear in response to rolling contact by the rolling element122. Such materials could be softer than the rolling element, such as steel, Inconel, titanium, or another metal with the desired hardness. The material could be one of various grades of carbide with differing cobalt contents to more precisely control the krevs/footage needed to displace the rolling element. The material could be steel with a carbide coating, such as laser-deposited carbide or HVOF, to vary the rate at which the roller begins to lose exposure. The material could be a matrix or ceramic material. The thickness of the bearing element or housing wall can be varied in addition to the material to control the krevs/footage drilled before the element disengages with formation. The roller could instead be made of a softer material than the retainer, such that is wears down enough that it no longer can be held by the retainer and escapes during the run. Foregoing embodiments provide examples of “deactivation” of the rolling element122, whereby the rolling element122initially limits the engagement of the cutting element to the formation and the corresponding depth of cut, and then moves inward to increase the engagement and depth of cut. Thus, the second exposure position is inward of the first exposure position. The rolling element122may move far enough inward so as to not appreciably limit depth of cut in the second exposure position. This deactivation of the rolling DOCC element is considered a “one-time deactivation” if the movement is one-way. Embodiments may also be constructed that provide “activation” of the rolling element downhole, wherein the rolling element122moves outwardly instead of inwardly. Thus, the second exposure position is outward of the first exposure position. By moving outwardly, the rolling element122limits depth of cut more in the second exposure position than in the first exposure position. This movement may also be one-way, in which case it may be considered a one-time activation of the rolling element. FIG.20is another example of a rolling DOCC assembly230that provides one-time activation of the rolling element122. The rolling element122is initially captured in the retainer housing124by a retention member, embodied by way of example as a cap232on the retainer housing124. The depth of engagement d1in this first exposure position is relatively large, such that little or no depth of cut limiting is provided by the rolling element122. A biasing member234, such as a spring, is disposed in the retainer housing124to bias the rolling element122outwardly. Alternatively, fluid pressure may be supplied from below the rolling element122to bias the rolling element122outwardly. The rolling element122is initially trapped below the cap232and initially retained in this first exposure position that provides little or no initial depth of cut control. The cap232is configured to fail or disintegrate downhole, similar to the retention members in the previous example embodiments, at which point the rolling element122may be urged upward by the biasing member. FIG.21is the rolling DOCC assembly230ofFIG.20, wherein the cap232has been removed, disintegrated, failed, or otherwise eliminated, so that the rolling element122may move outwardly from the first exposure position to the second exposure position. The rolling element122is urged outwardly by the biasing member234to the second exposure position, which has a correspondingly reduced depth of engagement d2of the fixed cutter116. In that way, the rolling element122is now activated. The biasing member234may provide sufficient force in some embodiments to maintain the rolling element122in the second exposure position, to be considered a one-time activation of the rolling element122. Accordingly, the present disclosure encompasses depth of cut control assemblies for a drill bit that have moveable and optionally rolling DOCC elements to change their exposure and the corresponding engagement of cutters during drilling. Rather than moving back and forth between exposure positions, the DOCC elements in at least some embodiments are activated or deactivated once during drilling, with one-way changes in exposure. Related drill bits, drilling systems, and drilling methods incorporating the depth of cut control assemblies are also provided. Multiple embodiments are disclosed, while other embodiments may be formed from any suitable combination of the collective features of the multiple embodiments disclosed, including one or more of the following statements. Statement 1. A drill bit comprising: a bit body securable to a drill string; a plurality of blades extending from the bit body; a plurality of fixed cutters secured to the blades; at least one depth of cut control (DOCC) element positioned in a retainer pocket along the blade to limit a depth of cut of one of the fixed cutters; and a retention member initially retaining the DOCC element within the retainer pocket at a first exposure position, the retention member configured to release the DOCC element downhole to allow one-way movement of the DOCC element to a second exposure position. Statement 2. The drill bit of Statement 1, further comprising a one-time deactivation configuration wherein the one-way movement of the DOCC element from the first exposure position to the second exposure position increases the depth of cut allowed by the DOCC element. Statement 3. The drill bit of Statement 1 or 2, further comprising a one-time activation configuration wherein the one-way movement of the DOCC element from the first exposure position to the second exposure position decreases the depth of cut allowed by the DOCC element. Statement 4. The drill bit of Statement 3, further comprising: a biasing element configured for biasing the DOCC element from the first exposure position to the second exposure position in response to the release of the DOCC element by the retention member. Statement 5. The drill bit of Statement 1, wherein the retention member is engaged by the DOCC element to release the DOCC element downhole by yielding in response to a threshold force applied to the DOCC element. Statement 6. The drill bit of any of Statements 1 to 5, wherein the retention member comprises a disintegrating material to release the DOCC element downhole by disintegrating downhole in response to an increase in temperature or exposure to a downhole fluid. Statement 7. The drill bit of any of Statements 1 to 6, wherein the DOCC element is rotatably secured by the retainer pocket when in one or both of the first exposure position and the second exposure position. Statement 8. The drill bit of Statement 7, wherein the retention member comprises a wearable material to release the DOCC element to the second exposure position in response to rolling of the DOCC element against the wearable material while drilling. Statement 9. The drill bit of Statement 8, wherein the wearable material comprises an outer layer of harder wearable material over an inner layer of softer wearable material. Statement 10. The drill bit of any of Statements 7 to 9, wherein the DOCC element is trailing the one of the fixed cutters. Statement 11. The drill bit of any of Statements 7 to 10, further comprising: a main cutting structure comprising a plurality of fixed cutters secured along the blades; and wherein the DOCC element is configured for cutting as part of the main cutting structure in at least the first exposure position. Statement 12. The drill bit of any of Statements 1 to 11, wherein the retention member comprises a shape memory material configured to release the DOCC element downhole by changing shape in response to reaching a threshold temperature. Statement 13. The drill bit of any of Statements 1 to 12, wherein the retention member comprises a shear member configured to shear in response to a threshold force or a burst disc configured to burst in response to a threshold pressure. Statement 14. A method, comprising: drilling a wellbore by engaging an earthen formation with a drill bit comprising a plurality of fixed cutters secured to blades extending from a bit body, by rotating the bit body around a bit axis to cut the earthen formation with the plurality of fixed cutters; limiting a depth of cut of at least one of the fixed cutters by engaging the formation with a depth of cut control (DOCC) element spaced from the one of the fixed cutters while initially retaining the DOCC element at a first exposure position; and releasing the DOCC element downhole to move the DOCC element to a second exposure position. Statement 15. The method of Statement 14, further comprising a one-time deactivation wherein moving the DOCC element from the first exposure position to the second exposure position comprises increasing the depth of cut allowed by the DOCC element. Statement 16. The method of Statement 14 or 15, further comprising a one-time activation wherein moving the DOCC element from the first exposure position to the second exposure position comprises decreasing the depth of cut allowed by the DOCC element. Statement 17. The method of any of Statements 14 to 16, further comprising: rotating the DOCC element relative to the bit body while rotating the drill bit around the bit axis in one or both of the first exposure position and the second exposure position. Statement 18. The method of Statement 17, further comprising: rolling the DOCC element against an outer layer of wearable material to wear though the outer layer of wearable material to an inner layer of wearable material while drilling a first portion of the wellbore; and rolling the DOCC element against the inner layer of wearable material while drilling a second portion of the wellbore. Statement 19. The method of any of Statements 14 to 18, further comprising: cutting the formation with the DOCC element along with the plurality of fixed cutters while the DOCC element is in the first exposure position; and using the DOCC element to limit the depth of cut of the one of the fixed cutters after moving the DOCC element to the second exposure position. Statement 20. A drilling system, comprising: a drill string; a drill bit comprising a bit body secured to a lower end of the drill string and rotatable about a bit axis, the drill bit including a plurality of blades extending from the bit body, a plurality of fixed cutters secured to the blades, and a plurality of depth of cut control (DOCC) elements positioned in respective retainer pockets along the blades to limit a depth of cut of the fixed cutters; and a retention member initially retaining each DOCC element within the respective retainer pocket at a first exposure position, the retention member configured to release the DOCC element after drilling to a depth downhole to allow one-way movement of the DOCC element to a second exposure position. To facilitate a better understanding of the present invention, the following examples of certain aspects of some embodiments are given. In no way should the following examples be read to limit, or define, the entire scope of the disclosure. For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited. Therefore, the present embodiments are 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 embodiments may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Although individual embodiments are discussed, all combinations of each embodiment are contemplated and covered by the disclosure. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. 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. | 55,519 |
11859452 | DETAILED DESCRIPTION A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures. Referring toFIG.1, a wet connect system10is illustrated. The system10comprises a first connector housing12having a first communication line14(seeFIG.10) therein. Line14is disposed within a wall of the housing12extending therealong for some distance. A second connector housing16is concentrically positionable within the first connector housing12. Second connector housing16includes a second communication line18(seeFIG.5) within a wall thereof. The first and second connector housings12and16are positionable such that a port156of first communication line14and a counter port158of second communication line18may be communicated to one another through a manifold area24defined radially by the first housing12and the second housing16and axially by seals160and162Further, a balance piston30is disposed in the first housing12and functions to ensure pressure of a clean hydraulic fluid remains essentially the same (e.g., hydrostatic pressure) as a pressure of fluid in the first communication line14so that debris does not get into the first communication line14during portions of operation when the manifold area24is not sealed. The balance piston30is sealed to the first housing12and to a sleeve32within the housing12. Referring toFIGS.2and3, the sleeve32is movable within the housing and spaced therefrom to produce an annular space34between the sleeve32and the housing12. It is in this space that the piston30may move in order to ensure that fluid disposed in the annular space between the balance piston30and the first communication line14(seeFIG.10) remains at hydrostatic pressure such that no debris is forced into line14. The position of the balance piston30is illustrated with the sleeve32in the open position inFIG.2and the closed position inFIG.3. Referring toFIGS.1and4, the system10also includes a running latch35. The running latch35is commercially available as a part of Baker Hughes' SureConnect™ connection movement restriction device, that is ordinarily used for running in the borehole, hence the name running latch used herein. Latches such as this have not however ben employed heretofore in connection with a set connect system such as system10since there has been no need to cause the systems of the prior art to carry weight until specifically released. The capability employed here is important to facilitate A one trip system where the weight of the lower completion must be supported. The running latch35maintains a load carrying configuration until it is hydraulically released. Referring toFIG.5, there is illustrated in the second communication line18an optional rupture disk36that may be employed to ensure the fluid within communication line18be clean at least until the disk36is ruptured. Referring toFIG.6, an open/close latch system110, that is usable with system10or otherwise, is illustrated. System110is configured to engage and latch the sleeve32that includes a profile114in order to move that sleeve32from an unactuated position to an actuated position and back to an unactuated position. As disclosed herein, the system110is configured to take this action with only a straight push and straight pull action, thus simplifying the process while also being reliable. The system110comprises a plurality of rocker latches120that are distributed about a rocker support122. The number of rocker latches120could be one but one would introduce side loads that would be less desirable and accordingly the system110uses a plurality of rocker latches in even or odd number. Each of the rocker latches120include an insertion face124having an angle that helps the rocker latches120deflect radially inwardly when contacting a reception face126of the profile114. After the insertion face124passes the reception face126, a seal face123comes into contact with the reception face126. In embodiments, seal face123and reception face126have differing angles from each other relative to a reference such as a longitudinal axis of the system10. The difference in angle helps to create a seal between the faces as the system10is manipulated. Further, in embodiments, it is contemplated to add a seal material to face123, face126or both. The seal material may be a softer material such as rubber, composite, or soft metal, for example, and serves the same purpose to enhance a seal between the faces during manipulation of the system10. For clarity, the optional seal material is illustrated with numerals125(at face123) and127(at face126) inFIG.6. Each rocker latch also has in an embodiment, a rocker recess128having a geometry that contributes to ease of radially inward deflection of the rocker latches120. In an embodiment, the recess has a curved geometry130at one end interacting with a rocker pivot132of the support122. It will be appreciated that the rocker pivot132may include a curved end134that interacts with the curved geometry130when the rocker latch120is deflected radially inwardly. Urging the insertion face124of the rocker latches120in the radially outward direction is a resilient retainer136that may in some embodiments comprise a snap ring or similar. The retainer136will help the rocker latches120engage a catch138of the latches120with a hold face140of profile114. In order to prevent disengagement of the catch138and hold face140at an inappropriate time, a movement restrictor142, which may be a dog in some embodiments, is positioned to interfere with a back end144of each latch120. Specifically, when the dog reaches a seal bore146of the sleeve32, the dog is pushed radially inwardly and not permitted to move radially outwardly while resident in the seal bore146. While dog142cannot move radially outwardly, the rocker latches120cannot rock about the rocker pivot132to allow the insertion face124to move radially inwardly. Accordingly, while the system110including the dog142is in the seal bore146, the latches120remain engaged and locked with the profile114. Movement of a string148upon which the system10is mounted will thus move the sleeve32with a simple push or pull movement of the string. With these components introduced reference is made toFIGS.6-10sequentially since they show the system110moving into and out of engagement with the sleeve32of wet connect system10FIG.6shows the system110having reached the profile114after being run in the hole.FIG.7illustrates what happens in the system110with continued downhole movement of the system110relative to the sleeve32. It will be appreciated fromFIG.7that the latches120are deflected inwardly so that the catch138of each latch120, which includes the insertion face124, can reposition to move past the reception face126and lockingly engage profile114. Note that it is possible for the latches120to move in this way at this stage illustrated inFIG.7because the dogs142are not yet within the seal bore146and hence can be pushed radially outwardly by the back end144of latches120. Moving toFIG.8, such movement of the latches120is no longer possible since the dogs142are now in the seal bore146and cannot move radially outwardly. In this condition the system110is firmly connected to sleeve32and sleeve32will move either downhole or uphole based simply upon a push or a pull, respectively, on the string148. The sleeve32may have many different actuation operations associated with it to operate many kinds of tools that need the sleeve to be repositioned. One specific example is a wet connect since the sleeve32may be employed to cover or uncover hydraulic ports156that are used to flush a connection area clean of debris and are to be protected when not in use. In theFIG.9view, the wet connect hydraulic ports156are closed. The sleeve32has been moved uphole by a pull on the string148and catch138interacting with hold face140transfers that pull to the sleeve32. Also, to be appreciated inFIG.9is that dogs142are no longer in the seal bore146and accordingly can now move radially outwardly. With this mobility, rocker latches120back ends144may also move radially outwardly as a consequence of the catch138moving radially inwardly to clear the profile114. This action is in progress in theFIG.9view, which also shows the ports156closed off by seal157. Referring toFIG.10, a particular embodiment where a wet connect is the tool10being actuated, the hydraulic ports156are seen open inFIG.10allowing fluid communication into counter ports158between seals160and162. Referring toFIG.11, a borehole system170is illustrated. The system170comprises a borehole172in a subsurface formation174. A string176is disposed within the borehole172. A latch system110is disposed within or as a part of the string176. Set forth below are some embodiments of the foregoing disclosure: Embodiment 1: A latch system including a plurality of rocker latches, a rocker support, supporting the plurality of rocker latches, and a movement restrictor in operative connection with each rocker latch of the plurality of rocker latches, the movement restrictor allowing or restricting movement of each rocker latch of the plurality of rocker latches relative to the rocker support. Embodiment 2: The latch as in any prior embodiment wherein the plurality of rocker latches include insertion faces that collectively form part of a frustum. Embodiment 3: The latch as in any prior embodiment wherein the insertion faces are at an angle to a longitudinal axis of the system that is different from an angle to a longitudinal axis of the system of a reception face of a separate sleeve with which the latch system engages, during use. Embodiment 4: The latch as in any prior embodiment wherein the insertion face, the reception face or both the insertion face and reception face include a seal material. Embodiment 5: The latch as in any prior embodiment wherein each of the plurality of rocker latches includes a rocker recess shaped to facilitate rocking movement on the rocker support. Embodiment 6: The latch as in any prior embodiment wherein each of the plurality of rocker latches includes a catch. Embodiment 7: The latch as in any prior embodiment wherein the rocker support is a cage. Embodiment 8: The latch as in any prior embodiment wherein the movement restrictor is a dog. Embodiment 9: The latch as in any prior embodiment wherein the dog includes a seal to prevent debris accumulating adjacent the dog. Embodiment 10: The latch as in any prior embodiment further including a resilient retainer tending the plurality of rocker latches to a latched position. Embodiment 11: A downhole tool including a sleeve movable relative to other portions of the tool, the sleeve having a profile at an uphole end thereof, an actuator runnable into contact with the sleeve, the actuator including the latch system as in any prior embodiment. Embodiment 12: The tool as in any prior embodiment wherein the tool is a wet connect. Embodiment 13: A borehole system including a borehole in a subsurface formation, a string in the borehole, and a latch system as in any prior embodiment disposed within or as a part of the string. Embodiment 14: A wet connect system including a first connector housing having a first communication line therein, a second connector housing concentrically positionable in the first connector housing and having a second communication line, and a balance piston fluidly connected to the first communication line. Embodiment 15: The system as in any prior embodiment wherein the balance piston connection to the first fluid communication line is in an annular space between the first connector housing and a sleeve therein. Embodiment 16: The system as in any prior embodiment further comprising a running latch having a locking sleeve. Embodiment 17: The system as in any prior embodiment further comprising a sleeve latch, the sleeve latch having a plurality of rocker latches, a rocker support, supporting the plurality of rocker latches, and a movement restrictor in operative connection with each rocker latch of the plurality of rocker latches, the movement restrictor allowing or restricting movement of each rocker latch of the plurality of rocker latches relative to the rocker support. Embodiment 18: The system as in any prior embodiment further comprising a running latch having a locking sleeve. Embodiment 19: The system as in any prior embodiment further comprising a rupture disk segregating a fluid of the second communication line until rupture of the disk. The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Further, it should be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. The terms “about”, “substantially” and “generally” are intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. For example, “about” and/or “substantially” and/or “generally” can include a range of ±8% or 5%, or 2% of a given value. The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a borehole, and/or equipment in the borehole, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc. While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. | 15,278 |
11859453 | DETAILED DESCRIPTION According to some embodiments, an apparatus for mounting on a tubular structure that traverses a hole is provided. The tubular structure may, for example, be a pipe string such as a casing string or a drill string. The tubular structure may also be a coiled tubing structure, for example. The apparatus may be used in various downhole operations. The apparatus may rotate independently of the tubular structure. In some embodiments, the apparatus may comprise a plurality of directionally spiraled, offset, ridges having non-uniform heights. The ridges may induce the rotation. For example, the ridges may all be angled in a same direction from the axial direction. Thus, the ridges may collectively have a generally right or left-handed spiral-like orientation to induce the rotation responsive to friction between the apparatus and the wall of a hole (e.g. wellbore) as the apparatus traverses the hole. The ridges in some embodiments may also be referred to as “blades” herein. The ridges may intermittently lift the tubular structure while the apparatus is rotating, thereby reducing or mitigating friction. The apparatus may be used, for example, in oil or gas well applications, although other applications are also possible. For example, the apparatus may be used for downhole applications including, but not limited to drilling, casing, well completion, cementing and well servicing applications, as well as various geothermal applications. Some embodiments described herein may be used in any application in which sections of pipe (i.e. a pipe string) or other tubular structure traverse a hole. Some embodiments provide a method and apparatus for reducing and or preventing problematic friction between a tubular structure (e.g. casing or drill string or coiled tubing), and the walls of a hole, such as a wellbore. The apparatus may be particularly useful in the build section and the horizontal sections of a well design, although embodiments are not limited to use in these areas of a well. The apparatus, when mounted on a tubular structure, may be pushed along the hole (e.g. wellbore) by a coupling, stop collar, crossover (XO) sub, or other structure having a widened section. When pushed along the hole, the friction against the apparatus may cause the apparatus to rotate. Rotation of the apparatus may cause intermittent raising and lowering of the tubular structure and apparatus, thereby reducing friction between the tubular structure and the walls of the hole. Some embodiments of the apparatus may harness friction created between the tubular structure (e.g. casing or drill string or coiled tubing) and the well bore to actuate or drive rotation of the apparatus to thereby reduce or minimize the friction. The apparatus may be installed over the outside diameter of the tubular structure (e.g. casing or pipe section), creating contact between the walls of the wellbore and the apparatus. Friction applied on the apparatus, through movement of the tubular structure in the hole, may drive rotation of the apparatus. FIG.1is a perspective view of an apparatus100for mounting on a tubular structure (not shown) such as a casing or drill string, or coiled tubing. The apparatus100may, for example, be mounted over a pin end of a casing string (or other pipe string). A coupling between casing sections (not shown) may push the apparatus100through a wellbore. Alternatively, a stop collar (not shown) may be used to push the apparatus100. The apparatus100may also be used on a drill string, for example, rather than a casing string. For installation on a drill string, a crossover (XO) sub (not shown) may be used to accommodate the apparatus100. The apparatus100may be mounted on the XO sub on a drill string. The XO sub may match up to the threads of the chosen drill string. Embodiments described herein are not limited to use with casing strings, drill strings or coiled tubing. Embodiments may also be utilized with other types of tubular structures for traversing a hole (such as a wellbore or other narrow hole). The apparatus100includes a tubular section or segment102for mounting over a tubular structure (such as a casing string section). In this example, the tubular segment102is sized for fitting over a casing section, but embodiments are not limited to use with casing, as discussed above. The tubular segment102has a first end103and a second end104opposite to the first end103. The inner diameter of the tubular segment102is larger than the outer diameter of the casing to which it is to be mounted, such that the apparatus100can freely or independently rotate about the casing. Specifically, in this example, the tubular segment102defines a hole105therethrough, and has an inner face106and an outer face108. The hole105is thus sized to fit over the casing. The inner diameter of the hole105may only be slightly larger than the outer diameter of the casing. Various embodiments of the apparatus may be sized to fit over various diameters of casings. Example casing diameters include, but are not limited to 4.5 inches, 5 inches, 20 inches, etc. The apparatus100may be placed over a pin end of a section of the casing at the drilling floor, for example. The apparatus100may then be lowered into the wellbore together with the section of the casing. The apparatus100may slide along the length of the casing until it is restricted and/or pushed by the couplings between casing sections, which typically have a greater diameter than the remainder of the casing. Alternatively, additional securing means, such as stop collars, may be placed at either end of the apparatus100to spot or secure the apparatus100to a particular lengthwise position on the casing section. Any suitable means of restricting movement of the apparatus100lengthwise along the casing (or other tubular structure) may be used. The apparatus100includes a plurality of ridges110aand110bevenly spaced around a circumference of the outer face108of the tubular segment102. The ridges110aand110bmay be in the form of blades. The ridges110aand110bare angled with respect to the axial direction of the tubular segment102, and as the apparatus100slides against the wall of a wellbore, the ridges110aand110bmay rotate the apparatus100as the apparatus100is pushed through the hole. In other words, friction between the wellbore walls and the apparatus100drives rotation of the apparatus100. In this embodiment, the ridges110aand110bare helical or spiral, with a right-handed rotation (from the first end103). The ridges110aand110beach extend approximately from the first end103to the second end104of the tubular segment102. From the first end103to the second end104of the tubular segment, the ridges110aand110beach revolve around approximately one quarter of the circumference of the tubular segment102. Thus, the four ridges110aand110bcollectively extend around the entire circumference of the tubular segment102. The angle and/or amount of spiraling of the ridges may vary in other embodiments. The ridges110aand110binFIG.1have a non-uniform height from the outer face108. The ridges110aand110beach include a respective lower section112aand112band a respective raised section114aand114b. The lower sections112aand112bextend a first distance from the outer face108of the tubular segment102(i.e. having a first height), and the raised sections114aand114bextend a second, greater distance from the outer face108(i.e. having a second, greater height). The ridges110aand110bare spaced around the circumference of the tubular segment102with alternating lengthwise orientations. The ridges110aand110balternate between: the raised section114abeing located at or near the first end103of the tubular segment102; and the raised section114bbeing located at or near the second end104of the tubular segment102. Thus, two of the ridges110ahave the raised section114aat the first end103of the apparatus100, and the other two ridges110bhave the raised section114bat the second end104. The ridges110aand110bare equally spaced apart in this embodiment, although ridges may not be equally spaced apart in other embodiments. In this embodiment, there are a total of four ridges110aand110b, although the number of ridges may vary. For example, tools with larger diameters may include more ridges than tools with smaller diameters. In another embodiment, the apparatus is adapted for use on a 5-inch casing and includes 4 ridges. In another embodiment, the apparatus is adapted for use on a 7-inch casing and includes 6 ridges. The number of ridges may be an even number so that the ridges can alternate in orientation similar to the ridges110aand110bshown inFIG.1. Other combinations are also possible, and embodiments are not limited to a particular number or orientation of ridges for a particular casing diameter. Each ridge110aand110bin this embodiment is chamfered or beveled at each of its ends116and118to the outer face108of the tubular segment102, although this is optional. The chamfering at ends116and118of the ridges110may an angle of approximately 67.5 degrees with respect to the radial direction, although embodiments are not limited to any particular angle. The tubular segment102may be chamfered, and the chamfering of the ridges110aand110bmay be flush with and/or have the same angle as the chamfering. FIG.2is a side view of the apparatus100ofFIG.1. In this embodiment, the lengths “L1” is the axial length of the two raised sections114aof the ridges110astarting at the first end103of the tubular segment102. The length “L3” is the axial length of the two raised sections114bof the ridges110bstarting at the second end104of the tubular segment102. Length “L2” is the distance between L1and L3. Each of L1, L2and L3are approximately equal in this embodiment. Specifically, these lengths are each approximately 4 inches each in this example, giving a total length of 12 inches. However, the lengths L1, L2and L3shown inFIG.2may vary. The ridges110aand110bhave opposing side walls124and126that extend outward from outer face108of the tubular segment102. The lower sections112aand112bof the ridges110aand110beach have a respective outward facing surface120(between side walls124and126), and the raised sections114aand114balso each have a respective outward facing surface122(between side walls124and126). The raised sections114aand114balso each include a short tapered surface123that tapers from the height of the raised sections114aand114bto the height of the lower sections112aand112b. The angle of the tapering between heights of the lower sections112aand112band the raised sections114aand114bmay match the angle of the chamfering at the ridge ends116and118. Embodiments are not limited to any particular shape of the ridges/blades. For example, the ridges could be blades in the form of narrow flanges, or the ridges may be wider than shown inFIGS.1and2. The ridges may have various cross-sectional shapes (rectangular, triangular, etc.). Instead of continuous helical ridges along the length of the apparatus100, other embodiments may include non-continuous ridges of varying lengths and configurations. For example, several short flanges, blades or other ridge-like structures may arranged at one or more angles to the axial direction and at various positions along the length of the tubular segment102. FIG.3is a reverse side view of the apparatus100ofFIGS.1and2showing the ridges110aand110band indicating total length LT, which is 12 inches in this example, although the length may vary. FIG.4is an enlarged partial side view of the apparatus100showing only the portion within the circle “A” shown inFIG.3. As shown inFIG.4, the tubular segment102has a thickness T1between the inner face106(shown inFIG.1) and the outer face108. The thickness T1is approximately 0.22 inches in this example, although the thickness may vary in other embodiments. As shown inFIG.4, the tubular segment102has an optional chamfer128between the outer face108and inner face106(shown inFIG.1). The chamfer128is angled at approximately 68 degrees with respect to the radial direction of the tubular segment102(matching the chamfering of the ridges110aand110b(shown inFIGS.1-3)), although this angle may vary. The optional chamfering or beveling may help avoid hang-up or snagging while the apparatus100travels through existing well components (e.g. a BOP (blow out preventer), surface casing, etc.) before the apparatus100reaches an open hole in the well bore. FIG.5is an end view of the apparatus100viewed from the second end104.FIG.5shows the ridges110aand110b, which are arranged in an alternating manner. The raised sections114bof two ridges110bare at the second end104. The other two ridges110ahave their raised sections114aat the first end103(shown inFIGS.1and2). As seen inFIG.5, the end-view, outer profile of the apparatus is non-circular and is closer to an elliptical shape, due to the alternating lengthwise orientation of the ridges110aand110b. FIG.6is a cross-sectional view of the apparatus100taken along the line B-B shown inFIG.3.FIG.6shows the lower sections112aof two ridges110aand the raised sections114bof the other two ridges110b. The inner diameter (ID) of the apparatus100is approximately 4.56 inches in this example. The outer diameter (ODT) of the tubular segment102is approximately 5.0 inches in this example The outer diameter (ODR) of the apparatus100, at the raised portions114aand114bof the ridges110aand110b, is approximately 6 inches in this example. The outer diameter (ODL) of the apparatus100, at the lower portions112aand112bof the ridges110aand110b, is approximately 5.5 inches in this example. However, the dimensions of the apparatus100may vary in other embodiments depending on several factors including, but not limited to, casing diameter, wellbore diameter, well type, material composition of the apparatus100, planned well operations and/or other factors. For example, the inner and outer diameters of the tubular segment102and the thickness of the tubular segment102may vary. The height, width, and shape of the ridges110aand110bmay also vary. As shown inFIG.6, the entire apparatus100is a unitary structure in this example. For example, the downhole apparatus described herein may be formed by a molding process and/or by any other suitable manufacturing means. That apparatus may be formed of any material suitable for use in a well, such as an oil and/or gas well. Possible materials include, but are not limited to, polymer, steel or alloy and/or a composite of more than one material. For example, if the apparatus100is made of L80 grade steel, it may be suitable for sour gas service. However, embodiments are not limited to L80 grade steel. The apparatus100may also be formed from a lightweight resin. Embodiments are not limited to any particular material or combination of materials. Other embodiments described herein may likewise be made of any suitable material including, but not limited to the examples discuss above. Embodiments are also not limited to the apparatus having a unitary structure. In other embodiments, the apparatus may be constructed of multiple materials and/or components. For example, the tubular segment could be formed separately from the ridges, and those two components could then be joined (e.g. using welding, adhesives, clamps, fastening hardware and/or other means). As one specific example, the tubular segment could be formed of metal, and metal ridges could be molded over the tubular segment. FIGS.7and8illustrate further details of the example lower sections112aand112band raised sections114aand114bof the apparatus100inFIGS.1to6. FIG.7is an enlarged partial view of the cross section shown inFIG.6, showing the portion within the circle “B” inFIG.6. The lower section112aextends a distance or height HLfrom the outer face108of the tubular segment102in the example ofFIG.7. Other lower sections112aand112bof the ridges110aand110bshown inFIGS.13,5and6have similar dimensions. The height HLis about 0.25 inches in this example, but the height will vary in other embodiments. FIG.8is an enlarged partial view of the cross-section shown inFIG.6, showing the portion within the circle “C” inFIG.6. The raised section114bextends a distance or height HRfrom the outer face108. In this example, H2is approximately 0.5 inches (although HRmay vary in other embodiments). As also shown inFIG.8, the side walls124and126of the ridges110bare angled with respect to each other, such that the ridge110bflares outward as it extends away from the tubular segment102. This flaring may provide a sharp, acute-angled side edges130and132between the outer facing surface122of the ridge110band the first and second side walls124and126respectively. The edges130and132may assist in driving rotation of the apparatus100because they may engage the wall of the wellbore more strongly or aggressively than softer edges (e.g. edges with 90 degree or wider angles and/or curved edges). In other words, the width of the ridge/blade increases in the outward direction from the tubular segment102. Thus, as shown, the ridges110bthus have a cross sectional profile similar to an isosceles trapezoid cross-sectional shape (with the outward facing surface122being the wide base). The angle α between the first wall124and the second wall126of the raised section114bis approximately 30 degrees in this example, although other angles may be used in other embodiments. The outer facing surface122of the raised section114bin this example has a width W1of approximately 1.43 inches. The first and second walls124and126of the raised section114btransition to outer face108of the tubular segment102with a slight curve having a radius of curvature (R0) of approximately 0.125 inches. However, the curvature or angle of transitions between various surfaces or faces of the apparatus100may vary, for example based on the curvature of milling tools used to create either the apparatus100or a mold for forming the apparatus100. In some embodiments, the outward facing surfaces of the ridges (such as the outward facing surfaces120and122shown inFIG.2) may define a slight groove (or other recessed or concave shape) along at least a portion thereof. The groove may, for example, be similar to the bottom surface of a hockey skate blade. For example, in the example ofFIG.8, the outward facing surface122of the raised section114bforms a shallow groove134with a depth HG. The depth HG of the groove134is approximately 0.01 inches (although this may vary). The groove may have a substantially flat surface with curved sides/edges near the first and second side edges130and132of the raised section114b. The sides of the groove in this example have an initial radius of curvature R1, which is approximately 0.25 inches (although this may vary). The curvature of the groove then softens between its sides to provide the 0.01-inch depth. The groove134in the outward facing surface122is almost as wide as the ridge110b. The distance from the groove134to the first and second walls124and126is shown as width “W2” inFIG.8. This width W2is approximately 0.063 inches in this example (although this may vary). The groove134may further assist the ridges110aand110bto aggressively grip or engage the wall of the wellbore to more efficiently convert frictional force into rotation of the apparatus. Raised sections114aand114bof the remaining ridges110aand110bshown inFIGS.1to3,5and6have similar dimensions and structure as the raised section114bshown inFIG.8. FIGS.9A to9Dillustrate the operation of the apparatus100in a wellbore150according to some embodiments.FIGS.9A to9Deach show an end view of the apparatus100and a cross-section of a casing154inside the apparatus100. The wellbore150has wellbore wall152. As the apparatus100moves with the casing through the wellbore150, there is friction between the apparatus100and the wellbore wall152. The wellbore is horizontal inFIGS.9A to9Dwith gravity pulling in the downward direction. As described above, in a build section or a horizontal section of a well, this friction can become problematic. However, the apparatus100may reduce overall friction as explained below. The friction of the wellbore wall152against the ridges110aand110bmay cause the apparatus to repeatedly rotate through the positions shown inFIGS.9A to9Das it traverses the wellbore. The non-circular (elliptical in this case) end-view profile of the apparatus100may cause intermittent lifting and lowering of the apparatus as it rotates. InFIGS.9A to9D, the rotation is in the counter clockwise direction as indicated by Arrow “A”. Starting fromFIG.9A, the apparatus rotates such that the raised sections114aand114brotate against the wall152of the wellbore150, the increased thickness of the raised sections114aand114braises the casing154away from the wellbore wall152for those portions of the rotation. The lower sections112aand112bof the ridges110aand110bmay temporarily not be in contact with the wellbore wall152as shown inFIG.9B. As the apparatus continues to rotate to the position ofFIG.9C, lower sections112aand112bmay fall against the wall152, thus lowering the casing154. The rotation continues through the position shown inFIG.9D, and the rotation may continue to repeat as long as the casing154and apparatus100traverse the wellbore. Thus, the rotation and non-circular design of the apparatus's ellipse design may create an intermittent lifting motion, interrupting the problematic friction between the walls of the well bore and the casing or drill string as it is extended and moves within the well bore. Such an intermittent lifting motion on the casing or drill string may reduce and/or prevent at least some problematic friction throughout operations of drilling the well bore, and/or running the casing string in the build and horizontal sections of the well bore, for example. Some embodiments of the apparatus described herein (such as apparatus100shown inFIGS.1to8) may, for example, provide over 8 rotations per minute (rpm) for a run speed of 32.08 feet/min (approx. 10 meters/min) movement of the apparatus through the wellbore. For a run speed of 66 feet/min (approx. 20 meters/min) through the wellbore, rotation of the apparatus100could possibly be approximately 16 rpm or more. For a run speed of 98 feet/min (approx. 30 meters/min) through the wellbore, rotation of the apparatus100could possibly be approximately 24 rpm. For a run speed of 164 feet/min (approx. 50 meters/min) through the wellbore, rotation of the apparatus100could possibly be approximately 41 rpm. However, embodiments are not limited to any particular rotation speed or to any particular ratio of rotation speed to movement through the wellbore. Fluids circulated in the wellbore may flow between adjacent ridges110aand110b(as well as in available space between the apparatus100and the wellbore wall). Thus, the apparatus100, mud, cement and other fluids that may be circulated around the casing (or other tubular structure) may not be substantially impeded by the apparatus100. Embodiments are not limited to the shape or structure of the example ridges110aand110bdescribed above. Other configurations are also possible. For example, in other embodiments, the ridges may have two ends with differing heights (one high, one low) and the outward facing surface of the ridges may taper along most or the entire length of the ridges between those two heights. The heights of such ridges may also be arranged in a lengthwise alternating manner similar to the other embodiments described herein. In other words, a first ridge/blade may have a raised point at or near a first end of the tubular core, while the next ridge/blade adjacent to the first blade has its raised point at or near the opposite second end of the tubular core. The arrangement of the ridges/blades may continue to alternate in such fashion. This alternating arrangement may result in a somewhat elliptical (non-circular) shape when viewing the apparatus at an end along the axial direction of the tubular core. When the apparatus is rotating around a center axis of the tubular core, the rotating ellipse shape may result in an intermittent lifting effect. The number of ridges/blades included in the apparatus may vary based on the diameter of the tubular structure to which it is intended to be mounted (e.g. casing or drill string, XO sub, coiled tubing, etc. The angle at which the ridges/blades spiral around the tubular core may vary depending on various factors, such as the length of the apparatus, the number of ridges, the inner and/or outer diameter of the apparatus, and/or the outer diameter of the ridges. The ridges/blades are not limited to a certain length, and may vary at least based on the spiral angle and the diameter size of the tubular structure for which a particular apparatus is intended. The height of the ridges/blades may vary, and embodiments are not limited to any particular height. For example, dimensions of the tubular core and the ridges/blades may be chosen to accommodate the diameter of the well bore for which the apparatus is intended. The number of ridges/blades in contact with the wall of the wellbore during rotation may vary according to the design of the apparatus. For example, inFIGS.9A to9D, the apparatus100is shown with a design where two adjacent ridges/blades110aand110btogether create lift because two raised sections114aand114bof the two ridges/blades are near the same point on the circumference of the tubular segment102. However, ridges/blades may include more than one raised section and/or the raised sections may be arranged so that only one, or more than two ridges/blades together provides lift as the device rotates. Embodiments are not limited to a particular number of ridges/blades being in contact with the wall(s) of the well bore during rotation. In the example, shown inFIGS.9A to9Bwith four ridges110aand110b, the casing is either lifted or lowered every 90 degrees of rotation of the apparatus100. With a greater number of ridges, the amount of rotation between lifting/lowering may be reduced. For example, for embodiments with six ridges, the lifting/lowering change may occur with every 60 degrees of rotation. For eight ridges, the lifting/lowering change may occur every 45 degrees of rotation. Other arrangements are also possible. Various example dimensions of an apparatus according to some embodiments are provided below. The outer diameter of the tubular segment and the inner diameter of the tubular segment may vary. For example, the outer diameter of the tubular segment of the apparatus may be in range of 2 inches to about 19 inches or more. The inner diameter may be in the range of about 1.5 inches to 18.5 inches or more. The thickness of the tubular segment may, for example, be in the range of approximately 0.2 to 0.5 inches. The total length of the tubular segment may be in the range of 6 to 24 inches or more. The length of the raised portions of the ridges (e.g. length L1or L3inFIG.2) may be in the range of 1 inches to 8 inches. It is to be understood that the ranges provided above are by way of example and embodiments are not limited to these ranges. The dimensions of the ridges or blades on the tubular segment may also vary. For example, height of the ridges at their lower sections (e.g. height HLinFIG.7) may be in the range of 0.25 to 1.5 inches or more. The height of the ridges at their raised sections (e.g. height HRinFIG.8) may be in the range of 0.1 to 1.5 inches or more. The width of the ridges (e.g. width W1inFIG.8) may be in the range of approximately 0.5 inches to 3.5 inches or more. It is to be understood that the ranges provided above are by way of example and embodiments are not limited to these ranges. Table 1 below shows several examples of approximate dimensions for tubular segments and the ridges/blades thereon according to some embodiments. It is to be understood that embodiments are not limited to these specific examples. In Table 1, “Tube Inner Diameter” refers to the inner diameter of the tubular segment. “Tube Outer Diameter” refers to the outer diameter of the tubular segment. “Ridge Outer Diameter” refers to the total outer diameter of the apparatus including the raised sections of the ridges. “Tube Length” refers to the entire length of the tubular segment. “Raised Section Length” refers to the length of the raised sections of the ridges, taken from the adjacent end of the apparatus (e.g. L1and L3inFIG.2). “Ridge Height (raised)” refers to the height of the raised sections of the ridges. “Ridge Height (lower)” refers to the height of the lower sections of the ridges. “Ridge Width” refers to the width of the ridges (e.g. W1inFIG.8). The heading “#Ridge” refers to the number of ridges on the tubular segment. All of the values provided in Table 1 are in inches. TABLE 1TubeTubeRidgeRaisedRidgeRidgeInnerOuterOuterTubeSectionHeightHeightRidgeDiameterDiameterDiam.LengthLength(raised)(lower)Width# of(in)(in)(in)(in)(in)(in)(in)(in)RidgeExample 14.65.06.012.04.000.500.251.444Example 24.65.06.017.06.500.500.251.444Example 34.65.06.024.08.000.500.251.444Example 44.65.06.012.04.150.500.441.444Example 55.15.56.512.04.150.500.441.694Example 65.66.17.312.04.150.600.541.884Example 75.66.18.312.04.000.480.231.704Example 85.66.17.012.04.000.480.421.704Example 95.66.17.312.04.251.100.482.024Example 105.66.18.312.04.000.600.251.456Example 116.16.58.312.04.150.850.792.144Example 126.16.58.312.04.000.860.362.144Example 136.77.49.012.04.000.800.181.726Example 146.77.48.312.04.000.430.051.724Example 156.77.49.012.04.150.800.741.726Example 166.77.48.312.04.000.430.372.144Example 177.17.78.412.04.000.420.171.506Example 187.17.78.512.04.000.360.111.486Example 197.17.78.412.04.150.360.301.486Example 207.78.59.512.04.000.500.251.706Example 217.78.59.512.04.150.500.481.696Example 228.79.610.512.04.000.440.192.016Example 238.79.610.512.04.100.450.392.016Example 249.710.612.012.04.000.690.311.576Example 259.710.612.012.04.000.690.631.578Example 2610.812.314.816.06.001.251.181.938Example 2711.812.814.816.06.001.000.941.938Example 2813.514.417.316.06.001.441.382.258Example 2916.117.019.816.06.001.381.312.588Example 3018.719.7023.516.06.001.901.833.008Example 3120.121.0823.516.06.001.151.093.078Example 321.52.03.56.01.500.750.250.754 Other variations are also possible. For example, the ridges may spiral in a left-handed or right-handed direction.FIG.10is a side view of an example apparatus200for mounting on a tubular structure (e.g. casing, drill string and/or tubular coil) according to another embodiment. The apparatus200comprises a tubular segment202and four ridges210thereon (similar to the apparatus100inFIGS.1to8). However, the ridges210of the apparatus200inFIG.10spiral in a left-handed direction (rather than right-handed) from a first end203. The direction of the spiraling may be chosen based on the desired rotational direction of the tools, and may also be based on a direction of rotation (if any) of the tubular structure on which the apparatus will be mounted. The length of the apparatus may also vary as shown in Table 1 above. As mentioned above, the example apparatus100inFIGS.1to8has a total length of approximately 12 inches.FIGS.11and12illustrate some other example lengths. FIG.11is a side view of an apparatus300(similar to the apparatus100inFIGS.1to8) according to some embodiments. The apparatus300includes a tubular segment302and spaced apart helical ridges310(arranged in an alternating manner). Each ridge310revolves or spirals around more than ¼ of the circumference of the tubular segment302. The tubular segment302has a total length (LT) of approximately 17 inches. The axial length (LR) of the raised portions314of the ridges310is approximately 6.5 inches. FIG.12is a side view of another apparatus400(similar to the apparatus100inFIGS.1to8) according to some embodiments. The apparatus400includes a tubular segment402and four spaced apart helical ridges410(arranged in an alternating manner). Each ridge410revolves or spirals around approximately ½ of the circumference of the tubular segment402. The tubular segment402has a total length (LT) of approximately 24 inches. The axial length (LR) of the raised portions414of the ridges410is approximately 8 inches. Turning again briefly toFIG.8, in that example, the outward facing surface122of the raised section114bforms a shallow groove134(similar to an ice skate blade). The remaining ridges110aand110bshown inFIG.1include similar grooves in their raised portions114aand114b, but the lower portions112aand112bdo not define such grooves in that example. In other embodiments, such grooves may extend along the lower (non-raised) portions of the ridges as well. In still other embodiments, ridges may not include any such grooves. FIG.13Ais a side view of another example apparatus500for mounting on a tubular structure (e.g. casing, drill string and/or tubular coil string, a completions string, and a well servicing string, etc.). The apparatus500includes a tubular segment502and four spaced apart helical ridges510(arranged in an alternating manner). Each ridge510includes a respective lower section512and a respective raised section514. FIG.13Bis an enlarged partial view of the portion of the apparatus500within the circle marked “D” inFIG.13A. As seen inFIG.13B, the lower section includes an outward facing surface521that is substantially flat with no groove. FIG.13Cis an enlarged partial view of the portion of the apparatus500within the circle marked “E” inFIG.13A. As seen inFIG.13C, the lower section includes an outward facing surface522that is also substantially flat with no groove. Thus, the ridges510in this example do not define an outward facing groove.FIGS.13B and13Calso show that the ridges510are chamfered to be flush with the chamfer517of the tubular segment502. In other embodiments, the outward facing surfaces of the ridges may curve slightly along the width of the ridges to be substantially parallel with the circumference of the tubular segment. As also mentioned above, in other embodiments, both the lower and raised sections of the ridges may define grooves along their length. The number of ridges also varies in other embodiments. For example, rather than four ridges, more or fewer ridges may be present.FIG.14Ais a perspective view of an apparatus600(similar to the apparatus100inFIGS.1to8) according to yet another embodiment. This embodiment may be particularly suited to applications requiring standoff between the casing (or other tubular structure) and the wellbore wall. Standoff may be required for cementing and/or completion operations. The apparatus600includes a tubular segment602and six (rather than four) spaced apart helical ridges610arranged in an alternating manner. The ridges610each rotate around approximately ⅙ of the outer circumference of the tubular segment602. FIG.14Bis a side view of the apparatus600ofFIG.14A. Each ridge610inFIG.14Bincludes a respective lower section612and a respective raised section614(similar to ridges110of the apparatus100inFIG.1). The ridges610are arranged on and extend outward from the outer face608of the tubular segment602. Each ridge includes first and second opposite chamfered ends618and619that are flush with the ends603and604of the tubular segment602. The angle of the chamfer is approximately 67.5 degrees with respect to the radial direction in this example. The total length LTof the apparatus600is approximately 12 inches, and the axial length LRof the raised sections614(starting at either end603or604of the apparatus) is approximately 4.15 inches in this example. The length LRmay range, for example, from one quarter to one half of the total length LTof the apparatus600, although embodiments are not limited to this range. Both the lower and raised sections612and614of the ridges610are grooved (similar to the blade of an ice skate) in this embodiment. FIG.14Cis an end view of the apparatus600for mounting on a tubular structure (e.g. casing, drill string and/or tubular coil, etc.).FIG.14Cshows the inner diameter (ID) of the tubular segment602, which is approximately 6.7 inches in this example. The outer diameter (ODT) of the tubular segment602is also shown, which is approximately 7.4 inches in this example. The outer diameter (ODR) of the apparatus at the raised sections614of the ridges610(seeFIG.14D) is approximately 9.0 inches in this example. The outer diameter (ODL) at the lower sections612(seeFIG.14D) is approximately 8.875 inches (only ⅛ of an inch less than at the raised sections). Thus, the raised sections614and lower sections612of the ridges610are close to the same height in this example, but the height difference may still induce sufficient intermittent raising and lowering of the apparatus600and tubular structure (e.g. casing or drill string, or coiled tubing, etc.) to reduce or mitigate friction, while possibly providing sufficient standoff for various well operations. FIG.14Dis a cross-sectional view of the apparatus600taken along the line “B” inFIG.14A. Thus, the line alternately intersects lower sections612and raised sections614of the ridges610. FIG.14Eis an enlarged partial view of the portion of the apparatus600within circle “F” inFIG.14D.FIG.14Eshows a lower section612of one of the ridges610. As shown, the lower section612extends a height HLfrom the outer face608of the tubular segment602. In this example, HLis approximately 0.74 inches (although HLwill vary in other embodiments). The side walls624and626of the ridge610are at an angle α to one another. The angle α is approximately 22 degrees in this example, although other angles may be used in other embodiments. In other embodiments, the angle α may be in the range of approximately 15 to 40 degrees (e.g. 15, 20, 30 degrees or more), although embodiments are not limited to this range. An outward facing surface622of the lower section612in this example defines a wide, shallow groove634with a width WG1of approximately 1.57 inches. The groove634in this example has a depth of approximately 0.005 inches, although other depths may also be used (e.g. 0.01 to 0.05 inches or more). The groove is almost as wide as the surface622, but leaves non-grooved portions635and636adjacent the side walls624and626. The non-grooved portions635and636are each approximately 0.063 inches wide in this embodiment. FIG.14Fis an enlarged partial view of the portion of the apparatus600within circle “G” inFIG.14Dshowing a raised section614of one of the ridges610. As shown, the lower section612extends a height HRfrom the outer face608of the tubular segment602. In this example, HRis approximately 0.8 inches (although HRwill vary in other embodiments). The angle α (22 degrees) is also shown inFIG.14F. The raised section614also has a slightly grooved or concave outward facing surface623. The groove636has a width WG2that is approximately 1.59 inches and is about 0.005 inches deep. Thus, the groove636is slightly wider than the groove634of the lower section612shown inFIG.14E. FIG.15Ais a perspective view of an apparatus700for mounting on a tubular structure (e.g. casing, drill string and/or tubular coil, etc.) according to yet another embodiment. The apparatus700includes a tubular segment702and eight spaced apart helical ridges710thereon, arranged in an alternating manner. The ridges710each rotate around approximately ⅛ of the outer circumference of the tubular segment702.FIG.15Bis a side view of the apparatus700ofFIG.15A. Similar to the ridges in other embodiments described herein, each ridge710inFIG.15Bincludes a respective lower section712and a respective raised section714. The ridges710extend outward from the outer face708of the tubular segment702. In this example, the tubular segment702has an inner diameter of approximately 18.7 inches. The ridges each have a height of about 1.83 inches at their lower sections712and about 1.9 inches at their raised sections714. This embodiment may, again, be suited to applications requiring a particular standoff due to the relatively small height difference between the lower sections712and the raised sections714. Ridges710may be approximately 3 inches wide. The lower and upper sections712and714for each ridge710are each slightly grooved (similar to the outer surfaces622and623of the grooves610inFIGS.14E and14F) respectively. The total length LTof the apparatus700is approximately 16 inches, and the length LRof the raised sections714(starting at either end703or704of the apparatus700) is approximately 6 inches in this example. As discussed and shown in table 1 above, the actual dimensions of the tubular segment702and ridges710may vary. The angle between side walls of the ridges710in this embodiment is approximately 15 degrees. As seen inFIG.15B, the ridges710are chamfered at the ends703and704of the apparatus. The length of the chamfering/tapering depends on the height of the ridges710and the angle of the chamfer. In this example, the angle is approximately 67.5 degrees. The height of the ridges is also chamfered between the lower section712and the raised section714. FIG.16shows still another example apparatus800for mounting on a tubular structure (e.g. casing, drill string and/or tubular coil). The dimensions of this apparatus800may conform to “Example 9” shown in Table 1 above. As indicated for one of the ridges810, the ridge includes a lower section812and a raised section814. The raised section814includes first and second beveled or chamfered sections820and822. The first chamfered section820tapers from the full height of the raised section814to the first end803of the tubular segment800. The second chamfered section822chamfers (in the opposite direction) to the height of the lower section812. The second chamfered section822ends where the lower section812begins. The height of the raised section814and angle of the chamfering is such that the first and second chamfered sections820and822form the majority of the raised section814and meet (or nearly meet) at peak824. The peak824comprises an outward facing surface826. The outward facing surface826is slightly grooved or concave similar to other examples described above. The remaining ridges810have a similar structure, but are arranged in an alternating manner. In some embodiments, the tubular segment and ridges/blades of the apparatus comprise two or more pieces or portions that may be coupled together and decoupled or disassembled. For example, the tubular segment and ridges may be divided into two or more pieces that may be assembled around a tubular structure (e.g. casing section). Thus, in the case of a casing string, the apparatus may not need to be placed over an end of the casing string section and may be mounted to a section of casing string section that is already coupled to other sections. Any suitable method to join or couple multiple pieces of the apparatus together may be used. FIG.17is an exploded perspective view of an example apparatus900for mounting on a tubular structure (e.g. casing, drill string and/or tubular coil) according to yet another embodiment. The apparatus900includes a first semi-tubular piece901and a second semi-tubular piece902that can be coupled together and decoupled. The first and second pieces901and902together form a tubular segment903with ridges910thereon (similar to the apparatus100inFIG.1). The tubular segment903and ridges910in this example are bisected along their length to form the first and second semi-tubular pieces901and902. The first and second pieces901and902can be placed around a tubular structure (not shown) and coupled together. The apparatus900inFIG.17also includes first and second clamps920and922that hold the first and second semi-tubular pieces901and902together. The tubular segment903(formed by the first and second semi-tubular pieces901and902) has first and second ends906and907and an outer face908. The outer face defines first and second annular, outer rabbet-type recesses930and932at the first and second ends906and907, respectively. The first clamp920comprises first and second semi-tubular pieces940and942, each having a respective outer face944and946and a respective inner surface948and949. The inner surfaces948and949collectively define an annular, inner rabbet-type recess950at one end951of the clamp920. The first clamp920is sized such that its inner rabbet-type recess950fits over and engages the outer rabbet-type recesses930of at the first end906of the tubular segment903. The first clamp920has inner and outer diameters that match the tubular segment. The first clamp920in this example include holes954and956for receiving fastening hardware (not shown) such as screws, bolts, etc. to fasten the first and second pieces940and942of the clamp920together. The second clamp922is structurally similar or the same as the first clamp920and includes first and second pieces960and962defining inner rabbet-type recess964for engaging the outer rabbet-type recesses932of at the second end907of the tubular segment903. FIG.18is a side view of the apparatus900ofFIG.17. InFIG.18, the first and second clamps920and922have engaged and coupled the first and second pieces901and902of the tubular segment903. The apparatus is mounted to a casing section970. The apparatus900may also be decoupled for removal from the casing section970(or from another tubular structure). Other clamp styles may also be utilized. In other embodiments other coupling hardware may be utilized including but not limited to clips, welding, adhesives, hinges, or other fastening hardware. Embodiments are not limited to any particular method of coupling and decoupling pieces of the apparatus. In other embodiments, the apparatus may comprise more than two pieces that can be coupled together to form the tubular segment and ridges. FIG.19is a partial side cross-sectional view of a wellbore1000with a casing string1002therein. A downhole apparatus1004(similar to the apparatus100inFIG.1) is mounted on the casing string. The apparatus includes ridges1005that are similar to the ridges110aand110binFIG.1. In this example, the apparatus1004is installed without using stop collars. Specifically, the apparatus is installed on a first casing section1006over a first coupler1008that couples the first casing section1006to a second casing section1010below it. The apparatus1004can slide and rotate freely on the first casing section1006. InFIG.19, the wellbore1000is vertical and wide enough that the apparatus1004is not yet encountering friction and, thus, sits on the first coupler1008. FIG.20is a partial side cross-sectional view of a wellbore1000with a casing string1002therein, but within the build section1003of the wellbore. As the first casing section1008(shown inFIG.19) carrying the apparatus1004reaches the build section, the apparatus1004encounters friction from the surface1012of the wellbore. Initially, when encountering friction, the apparatus1004may initially remain static while the first casing section1006continues to move forward, until the apparatus1004comes into contact with a second coupling1014above it. The second coupling1014couples the first casing section1006and a third casing section1016(which is above the first casing section1006). The second coupling1014may then push the apparatus1004through the wellbore1000. The friction of the ridges1005moving against the wellbore surface1012may cause the apparatus1004to rotate as discussed above. In this example, the rotation will be similar to the rotation shown inFIGS.9A to9D. This rotation may cause intermittent lifting and lowering, thereby mitigating friction. The rotation rate of the apparatus1004may depend on the run speed of the casing string. The apparatus1004may alternatively encounter friction and begin rotation while still in the vertical portion of the wellbore1000(shown inFIG.19) Since the apparatus1004may rotate independently of the casing string, the casing string may be circulated and/or rotated while the apparatus1004continues to rotate. Excessive torque on the casing string couplings may be minimized. As the casing string1002extends further into the horizontal section of the wellbore (not shown), the vertical force applied on the casing string1002may increase throughout the build section, where the risk of tubular buckling may be highest. The friction mitigation provided by the apparatus1004may reduce axial tension throughout the build section1003, thereby mitigating tubular buckling. It is to be understood that the figures described above are provided for illustrative purposes, and the curvature and dimensions shown therein are not necessarily to scale. The embodiments of the apparatus described herein may be used, for example, in wells that are intended to be cemented. However, some embodiments may be used in wells that are not to be cemented. The apparatus may be suitable for wells of various types and in various different well environments. Embodiments are not limited to a particular type of well. Similarly, embodiments are not limited to use in build and horizontal sections of wells. FIG.21Ais a perspective view of an example apparatus1100for mounting on a tubular structure (e.g. casing, drill string and/or tubular coil) according to yet another embodiment.FIG.21Bis a side view of the apparatus1100ofFIG.21A. The apparatus1100includes a tubular segment1102(with first end1103and second end1104) and ridges1110thereon similar to other embodiments described herein. The ridges1110in this example do not extend along the entire length of the tubular segment1102. Instead, the apparatus1100has first and second runout portions1112and1114at the first and second ends1103and1104respectively. The ridges1110stop at the runout portions1112and1114, not the first and second ends1103and1104of the tubular segment. FIG.22Ais a perspective view of an example apparatus1200for mounting on a tubular structure (e.g. casing, drill string and/or tubular coil) according to still another embodiment.FIG.22Bis a side view of the apparatus1100ofFIG.22A. The apparatus1200includes a tubular segment1202(with first end1203and second end1204). In this example, rather than continuous spiral ridges with lower and raised sections, the apparatus1200includes a plurality of lower ridges1212and a plurality of raised ridges1214. The ridges1212and1214are all angled from the axial direction in a generally right-handed manner from the first end1203. In this example, each lower ridge1212is aligned (lengthwise) with a corresponding raised ridge1214. The pairs of lower ridges1212and raised ridges1214are arranged in an alternating lengthwise orientation (similar to other embodiments described herein). FIG.22Cis an end view of the apparatus1200. As shown, the arrangement of the lower ridges1212and the raised ridges1214provides a non-circular, more elliptical end profile. Thus, the apparatus, when rotating, may still intermittently raise and lower with respect to the wall of a hole (e.g. wellbore). FIG.23Ais a perspective view of an example apparatus1300for mounting on a tubular structure (e.g. casing, drill string and/or tubular coil) according to still another embodiment.FIG.23Bis a side view of the apparatus1300ofFIG.23A. The apparatus1300includes a tubular segment1302(with first end1303and second end1304) and pluralities of lower ridges1312and raised ridges1314thereon. The ridges1312and1314are all angled similar to the apparatus1200inFIGS.22A to22C. However, in this example, the lower ridge1312are not aligned with the raised ridge1314. Nevertheless, the ridges are still arranged to provide a non-circular end profile. FIG.23Cis an end view of the apparatus1300. As shown, the arrangement of the lower ridges1312and the raised ridges1314provides a non-circular, more elliptical end profile. Thus, the apparatus, when rotating, may still intermittently raise and lower with respect to the wall of a hole (e.g. wellbore). According to some embodiments, a method for reducing friction in a well bore is provided.FIG.24is a flowchart of an example method. At block2402, the apparatus (having a tubular segment and ridges thereon) as described herein is mounted on a tubular structure, such as a casing string, a drill string or coiled tubing. The tubular structure may be a casing or drill string, for example. At block2404the tubular structure, with the apparatus mounted thereon, traverses a hole. The hole may be a well wellbore, for example. Traversing the wellbore may include lowering the tubular structure into the wellbore. In some embodiments, mounting the apparatus (block2402) may comprise placing the apparatus over an end of one of a plurality of sections of the tubular structure (e.g. a pin end of a casing section). In some embodiments, the apparatus comprises two or more pieces that couple together (such as the example inFIGS.17and18). Thus, mounting the apparatus (block2402) may comprise coupling the two or more portions about the tubular structure. The method may also include moving the apparatus, thus mounted, in a build or horizontal section of a well. It is to be understood that a combination of more than one of the above approaches may be implemented in some embodiments. Embodiments are not limited to any particular one or more of the approaches, methods or apparatuses disclosed herein. One skilled in the art will appreciate that variations and alterations of the embodiments described herein may be made in various implementations without departing from the scope thereof. It is therefore to be understood that within the scope of the appended claims, the disclosure may be practiced otherwise than as specifically described herein. What has been described is merely illustrative of the application of the principles of aspects of the disclosure. Other arrangements and methods can be implemented by those skilled in the art without departing from the scope of the claims. | 53,943 |
11859454 | DETAILED DESCRIPTION This disclosure describes an acoustic shale shaker for separating drill cuttings. The acoustic shale shaker includes a receptacle, a screen, acoustic transducers, plates, and collection pans. Drill cuttings and drilling fluid are collected into the receptacle and then transferred from the receptacle onto the screen. The acoustic transducers generate acoustic vibrations at a range of different frequencies to separate the drill cuttings by density. The plates help the separation process and also direct the separated drill cuttings into the individual collection pans. In some cases, the screen is tilted to facilitate separation of the drill cuttings and movement toward the collection pans. Each individual collection pan includes drill cuttings of similar density. The cuttings that have been distributed and separated into the different collection pans can be analyzed to determine characteristics of the subterranean formation from which the drill cuttings originated and for the presence and composition of hydrocarbons. The subject matter described in this disclosure can be implemented in particular implementations, so as to realize one or more of the following advantages. The apparatuses, systems, and methods described here can be implemented to separate drill cuttings based on their physical characteristics (such as density, size, and/or volume), such that drill cuttings having similar properties can be analyzed together. For example, the apparatuses described include acoustic transducers that are configured to generate acoustic vibrations having a range of frequencies, which can cause similar drill cuttings to aggregate, thereby facilitating the drill cuttings separation process. The separation of drill cuttings based on characteristics can facilitate the analysis of the subterranean formation from which the drill cuttings originated. The drilling fluid that has been stripped from the drill cuttings can be recovered and reused in the drilling process to minimize drilling fluid losses. FIG.1is a schematic diagram of an example shale shaker100. The shale shaker100is configured to separate drill cuttings from drilling fluid. The shale shaker100includes a receptacle102, a screen104, acoustic transducers106, and collection pans108. The receptacle102is configured to receive a mixture101of drill cuttings and drilling fluid, for example, from the annulus of the wellbore. In some implementations, the screen104is adjustable, such that the screen104can be rotated and/or tilted to facilitate travel of the mixture101across the screen104and separation of the mixture101. For example, the shale shaker100can include a motor coupled to the screen104, and the motor can adjust a position/angle of the screen104as desired. The receptacle102is positioned at a first end104aof the screen104. The screen104can have, for example, a square shape or a rectangular shape. The first end104aand the second end104bof the screen104can be opposite sides of the square or rectangular screen104. In some implementations, the receptacle102includes a feeder (such as a weir feeder) that evenly distributes the mixture of drill cuttings and drilling fluid along the entire width of the first end104aof the screen104. The receptacle102is configured to distribute the mixture of drill cuttings and drilling fluid across the first end104a(for example, the width) of the screen104. The acoustic transducers106are attached to the screen104. For example, the acoustic transducers106are in physical contact with a bottom side of the screen104, such that the acoustic transducers106can impart vibrations to the screen104without impeding travel of the mixture101across the top side of the screen104. The acoustic transducers106are configured to generate acoustic vibrations in a range of frequencies. The acoustic vibrations generated by the acoustic transducers106cause the screen104to vibrate, thereby facilitating the mixture of drill cuttings and drilling fluid to travel laterally across the length of the screen104(for example, in a general direction from the first end104ato the second end104b). The acoustic vibrations generated by the acoustic transducers106can cause the drill cuttings to separate, for example based on characteristics (such as density), as the mixture travels across the screen104. In some implementations, the screen104is a solid plate, and the mixture101travels across the top side of the solid plate while the acoustic transducers106coupled to the bottom side of the solid plate generate acoustic vibrations of varying frequencies. In some implementations, the screen104defines holes that are sized to allow the drilling fluid and drill cuttings of a specified size to fall through the screen104via the holes. The screen104can define holes that are uniform in size or varying in size. In some implementations, the screen104defines holes having an opening size in a range of from about 100 micrometers to about 6,000 micrometers. In some cases, substantially all of the drilling fluid falls through the screen104via the holes, while drill cuttings that are too large to fall through the screen104via the holes travel across the screen104. The drilling fluid that falls through the screen104via the holes can, for example, be recovered and re-used in drilling operations. The acoustic vibrations generated by the acoustic transducers106facilitate travel of the drill cuttings laterally across the screen104. The acoustic vibrations generated by the acoustic transducers106can facilitate the drill cuttings that are smaller than the holes of the screen104to fall through the screen104via the holes. The acoustic transducers106use electricity to generate acoustic vibrations. For example, the acoustic transducers106can include piezoelectric material that can convert electricity into acoustic vibration. In some implementations, the acoustic transducers106are configured to generate acoustic vibrations having variable (that is, adjustable) frequencies varying from 1 kilohertz to 10 gigahertz. For example, each acoustic transducer106is tunable and can generate acoustic vibrations that can vary in frequency in a range of from 1 kilohertz to 10 gigahertz, and the frequencies of the generated acoustic vibrations can be adjusted based on particular needs. In some implementations, at least one of the acoustic transducers106is configured to generate acoustic vibrations having a frequency that is different from the acoustic vibrations generated by a remainder of the acoustic transducers106. In some implementations, each of the acoustic transducers106is configured to generate acoustic vibrations having a different frequency (that is, each acoustic transducer106generates an acoustic vibration having a different frequency from the acoustic vibration generated from another acoustic transducer106). As one example, a first acoustic transducer can generate an acoustic vibration having a frequency of 10 kilohertz, a second acoustic transducer can generate an acoustic vibration having a frequency of 100 kilohertz, and a third acoustic transducer can generate an acoustic vibration having a frequency of 1 gigahertz. The acoustic transducers106can be made of, for example, quartz or a different piezoelectric material, such as crystalline materials, ceramics, semiconductors, or polymers. Including multiple acoustic transducers106that simultaneously generate acoustic vibrations of different frequencies can facilitate separation of dissimilar drill cuttings and can also facilitate congregation of similar drill cuttings. For example, the acoustic vibrations generated by the acoustic transducers106can have different frequencies, which can cause drill cuttings having similar properties (for example, density and/or composition) to congregate/aggregate while separating from drill cuttings having dissimilar properties. The collection pans108are positioned at a second end104bof the screen104that is opposite the receptacle102. That is, the receptacle102and the collection pans108are positioned at opposite ends of the screen104. In some implementations, the receptacle102is coupled to the first end104aof the screen104, and the collection pans108are coupled to the second end104bof the screen104. During operation of the shale shaker100, the collection pans108can be positioned below the receptacle102, such that the screen104extending from the receptacle102to the collection pans108deviates from a horizontal (reference horizontal dotted line inFIG.1) with respect to gravity. In some implementations, the screen104deviates from the horizontal by a degree (a) in a range of from about 1° to about 5°. The collection pans108are configured to receive at least a portion of the drill cuttings that have traveled across the screen104. In some implementations, as shown inFIG.1, the shale shaker100includes multiple collection pans108that are distributed side-by-side across the second end104bof the screen104. Although shown inFIG.1as including three collection pans108, the shale shaker100can include fewer (for example, one or two) or additional (for example, four, five, or more than five) collection pans108. In some implementations, the shale shaker100includes, for each pair of neighboring collection pans108, a plate110positioned intermediate of the respective neighboring collection pans108. Each plate110can be configured to facilitate separation of drill cuttings into the respective neighboring collection pans108. The plate(s)110can direct the drill cuttings to the collection pan(s)108. The inclusion of multiple collection pans108can be useful in collecting drill cuttings having similar properties in each collection pan. For example, the acoustic transducers106generating acoustic vibrations of different frequencies can cause the drill cuttings to separate based on properties, and similar drill cuttings can congregate and be directed into a particular collection pan108while other drill cuttings are directed to one or more different collection pans108. The drill cuttings collected by the collection pans108can be analyzed to determine characteristics of the subterranean formation in which the wellbore has been formed and from which the drill cuttings have originated. For example, the drill cuttings collected by the collection pans108can be analyzed to determine the presence and/or composition of hydrocarbons. The drilling fluid and/or the drill cuttings that have separated from the mixture101and fallen through the holes of the screen104can be collected, for example, in a settling pit positioned below the screen104(such as the settling pit236). The drilling fluid from the settling pit236can be transferred to the suction pit238. The drilling fluid then be flowed back into the wellbore by the fluid pump230, for example, to be re-used to drill deeper into the subterranean formation. In some implementations, at least a portion of the drill cuttings collected by the collection pans108can be recycled to the receptacle102for further separation. For example, the drill cuttings of the mixture101can be separated into the collection pans108while the acoustic transducers106generate acoustic vibrations having a frequency of about 8.5 kilohertz, and then a portion of the drill cuttings from the collection pans108can be re-processed by the apparatus100(and the collection pans108emptied) to be separated into the collection pans108while the acoustic transducers106generate acoustic vibrations with frequencies varying from about 8 kilohertz to about 9 kilohertz. The re-processing of drill cuttings using the apparatus100can reveal impurities and mineral composition (including cementations) associated with the drill cuttings and the subterranean formation from which they were obtained. FIG.2is a schematic perspective view of an example rig system200for drilling and producing a well. The well can extend from the surface through the Earth to one or more subterranean zones of interest. The example rig system200includes a drill floor202positioned above the surface, a wellhead204, a drill string assembly206supported by the rig structure, and a fluid circulation system208to filter used drilling fluid from the wellbore and provide clean drilling fluid to the drill string assembly206. For example, the example rig system200ofFIG.2is shown as a drill rig capable of performing a drilling operation with the rig system200supporting the drill string assembly206over a wellbore. The wellhead204can be used to support casing or other well components or equipment into the wellbore of the well. The derrick or mast is a support framework mounted on the drill floor202and positioned over the wellbore to support the components of the drill string assembly206during drilling operations. A crown block212forms a longitudinally-fixed top of the derrick, and connects to a travelling block214with a drilling line including a set of wire ropes or cables. The crown block212and the travelling block214support the drill string assembly206via a swivel216, a kelly218, or a top drive system (not shown). Longitudinal movement of the travelling block214relative to the crown block212of the drill string assembly206acts to move the drill string assembly206longitudinally upward and downward. The swivel216, connected to and hung by the travelling block214and a rotary hook, allows free rotation of the drill string assembly206and provides a connection to a kelly hose220, which is a hose that flows drilling fluid from a drilling fluid supply of the circulation system208to the drill string assembly206. A standpipe222mounted on the drill floor202guides at least a portion of the kelly hose220to a location proximate to the drill string assembly206. The kelly218is a hexagonal device suspended from the swivel216and connected to a longitudinal top of the drill string assembly206, and the kelly218turns with the drill string assembly206as the rotary table242of the drill string assembly turns. In the example rig system200ofFIG.2, the drill string assembly206is made up of drill pipes with a drill bit (not shown) at a longitudinally bottom end of the drill string. The drill pipe can include hollow steel piping, and the drill bit can include cutting tools, such as blades, discs, rollers, cutters, or a combination of these, to cut into the formation and form the wellbore. The drill bit rotates and penetrates through rock formations below the surface under the combined effect of axial load and rotation of the drill string assembly206. In some implementations, the kelly218and swivel216can be replaced by a top drive that allows the drill string assembly206to spin and drill. The wellhead assembly204can also include a drawworks224and a deadline anchor226, where the drawworks224includes a winch that acts as a hoisting system to reel the drilling line in and out to raise and lower the drill string assembly206by a fast line225. The deadline anchor226fixes the drilling line opposite the drawworks224by a deadline227, and can measure the suspended load (or hook load) on the rotary hook. The weight on bit (WOB) can be measured when the drill bit is at the bottom the wellbore. The wellhead assembly204also includes a blowout preventer250positioned at the surface201of the well and below (but often connected to) the drill floor202. The blowout preventer250acts to prevent well blowouts caused by formation fluid entering the wellbore, displacing drilling fluid, and flowing to the surface at a pressure greater than atmospheric pressure. The blowout preventer250can close around (and in some instances, through) the drill string assembly206and seal off the space between the drill string and the wellbore wall. During a drilling operation of the well, the circulation system108circulates drilling fluid from the wellbore to the drill string assembly206, filters used drilling fluid from the wellbore, and provides clean drilling fluid to the drill string assembly206. The example circulation system208includes a fluid pump230that fluidly connects to and provides drilling fluid to drill string assembly206via the kelly hose220and the standpipe222. The circulation system208also includes a flow-out line232, the shale shaker100, a settling pit236, and a suction pit238. In a drilling operation, the circulation system208pumps drilling fluid from the surface, through the drill string assembly206, out the drill bit and back up the annulus of the wellbore, where the annulus is the space between the drill pipe and the formation or casing. The density of the drilling fluid is intended to be greater than the formation pressures to prevent formation fluids from entering the annulus and flowing to the surface and less than the mechanical strength of the formation, as a greater density may fracture the formation, thereby creating a path for the drilling fluids to go into the formation. Apart from well control, drilling fluids can also cool the drill bit and lift rock cuttings from the drilled formation up the annulus and to the surface to be filtered out and treated before it is pumped down the drill string assembly206again. The drilling fluid returns in the annulus with rock cuttings and flows out to the flow-out line232, which connects to and provides the fluid to the shale shaker100. The flow-out line232is an inclined pipe that directs the drilling fluid from the annulus to the shale shaker100. The shale shaker100can include a mesh-like surface (such as the screen104) to separate the coarse rock cuttings from the drilling fluid, and finer rock cuttings and drilling fluid then go through the settling pit236to the suction pit238. The circulation system208includes a mud hopper240into which materials (for example, to provide dispersion, rapid hydration, and uniform mixing) can be introduced to the circulation system208. The fluid pump230cycles the drilling fluid up the standpipe222through the swivel216and back into the drill string assembly206to go back into the well. The example wellhead assembly204can take a variety of forms and include a number of different components. For example, the wellhead assembly204can include additional or different components than the example shown inFIG.2. Similarly, the circulation system208can include additional or different components than the example shown inFIG.2. FIG.3is a flow chart of an example method300for separating solids from a drilling fluid. The rig system200can, for example, implement the method300. The shale shaker100can, for example, be used to implement the method300. At block302, a mixture of drill cuttings and drilling fluid (such as the mixture101) is directed onto a screen (such as the screen104). The receptacle102positioned at the first end104aof the screen104can direct the mixture101onto the screen104at block302. At block304, acoustic vibrations having a range of frequencies are generated. The acoustic vibrations generated at block304facilitate travel of the mixture101across the screen104. The acoustic transducers106attached to the screen104can generate the acoustic vibrations at block304. At block306, the drill cuttings are separated. The acoustic vibrations generated at block304cause the drill cuttings to separate at block306. For example, the acoustic transducers106generate acoustic vibrations of varying frequencies at block304, which cause the drill cuttings to separate based on characteristics of the drill cuttings, such as density. At block308, a first portion of the drill cuttings that have traveled across the screen104are received by a first collection pan of the collection pans108. At block310, a second portion of the drill cuttings that have traveled across the screen104are received by a second collection pan of the collection pans108. A plate (such as one of the plates110) can direct the first portion of the drill cuttings to the first collection pan and the second portion of the drill cuttings to the second collection pan. While this specification contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of features that may be specific to particular implementations. Certain features that are described in this specification in the context of separate implementations can also be implemented, in combination, in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations, separately, or in any sub-combination. Moreover, although previously described features may be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can, in some cases, be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination. As used in this disclosure, the term “about” or “approximately” can allow for a degree of variability in a value or range, for example, within 10%, within 5%, or within 1% of a stated value or of a stated limit of a range. As used in this disclosure, the term “substantially” refers to a majority of, or mostly, as in at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more. Particular implementations of the subject matter have been described. Other implementations, alterations, and permutations of the described implementations are within the scope of the following claims as will be apparent to those skilled in the art. While operations are depicted in the drawings or claims in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed (some operations may be considered optional), to achieve desirable results. Accordingly, the previously described example implementations do not define or constrain the present disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of the present disclosure. | 22,151 |
11859455 | DETAILED DESCRIPTION OF THE INVENTION Referring toFIG.1, the automated drilling-fluid additive system and method10is shown schematically, in use in coiled-tubing drilling operations with varying mixtures of fresh and returned drilling fluid blended with desired additives provided to a high-pressure injection pump for injection into the well. In the embodiment shown inFIG.1, the automated drilling-fluid additive system and method10provides a blending unit40enclosing blending components as treated below, and a chemical-addition unit50as treated below. This embodiment is meant to be used with a holding tank41, in circumstances where a holding tank is used instead of providing blended drilling fluid directly to the coiled-tubing operation. The holding tank41can also be a mixing tank, if the blended drilling fluid needs additional mixing while being held in order to, for example, prevent settling or separating of additives. In the embodiment shown inFIG.2, the automated drilling-fluid additive system and method10provides a chemical-addition unit50which directly and separately supplies a mixing tank42with drilling fluid and the proper amount of each additive, to be blended in the mixing tank42before being supplied to the coiled-tubing operation. The drilling fluid blended with additives in the mixing tank42can optionally be either supplied directly to the coiled-tubing operation or can be held in a holding tank. Referring toFIG.3, the chemical-addition unit50provides an inline diagnostic unit3which takes real-time measurements of the flowing drilling fluid. The inline diagnostic unit3is mounted in the flow of drilling fluid in standard ways such as the 4-inch flanges shown. The inline diagnostic unit3further provides several sensors housed in a sensor housing52. The chemical-addition unit50provides multiple peristaltic pumps53for delivery of additives through separate cam-lock hose connectors54, with each peristaltic pump53having an input and output pair. The chemical-addition unit50provides a controller21, treated below, having a controller display51such as a touch screen monitor for displaying data and for taking user input. The chemical-addition unit50provides a controller communication unit25, treated below. The chemical-addition unit50also provides a frame for housing its components in a safe and sturdy manner appropriate to oilfield use. Referring back toFIG.1, standard totes31, each containing an additive, are placed on or near the chemical-addition unit50and are connected to the structure by tote fluid lines32. Each tote can be connected or disconnected for the purpose of replacing an empty tote or connecting totes with a different additive as needed for different phases of operations or different downhole conditions encountered. In use, drilling fluid is drawn from an inlet1at an upstream end, through an intake pump2, into the chemical-addition unit50, to the blending unit40, and through an outlet9at a downstream end. A conveyor pipe5runs through the blending unit40and provides a flow path for the drilling fluid. In a preferred embodiment the conveyor pipe5is bent to allow a long run of pipe within the blending unit40. The diameter of the conveyor pipe5varies, as treated below, but is on average larger than the diameter of the pipes attached at the inlet1and outlet9, and is at no point smaller. Drilling fluid is pushed, by the intake pump2, through the inline diagnostic unit3of the chemical-addition unit50, and into the blending unit40, through a conveyor pipe5and toward the outlet9. A moderate pressure of approximately 150 psi is appropriate. If the high-pressure injection pump slows enough to place back pressure on the intake pump2, the intake pump should lessen or stop the flow of drilling fluid through the conveyor pipe5. In an embodiment, the pressure imparted by the intake pump2can be significantly increased in order to meet a high demand for blended drilling fluid at the high-pressure injection pump. The incoming drilling fluid passes through an inline diagnostic unit3which takes real-time measurements of the flowing drilling fluid, from which measurements the viscosity and other qualities of the incoming drilling fluid can be determined. The instantaneous pressure and rate of flow of incoming drilling fluid is also measured. These measurements are conveyed to a controller21via a diagnostic-unit connector22. The controller21receives and processes instructions through a controller communication unit25which communicates with a remote communication unit26. In a preferred embodiment, the communication is local-area wireless, for communications on-site in locations possibly remote from wireless telephone signals, plus wide-area or telephone wireless for use when a signal is available. The controller21can also provide data and status conditions to the remote communication unit26. Based upon the received instructions for the desired qualities of a resulting blended drilling fluid, the controller21processes the data provided by the inline diagnostic unit3and determines what additives in what amount need to be added to the incoming drilling fluid, and what rate of flow of additives is appropriate to the instantaneous pressure and rate of flow of incoming drilling fluid. The incoming drilling fluid then flows into an expanding additive area3of the conveyor pipe5which has a larger cross-sectional area which creates a pressure drop in the flow of drilling fluid. Injection lines33corresponding to the tote fluid lines32are provided in the expanding additive area3. The additives in the totes31can flow into the lower-pressure expanding additive area3without having to overcome the resisting pressure existing elsewhere in the conveyor pipe5. The flow of additives from the totes31through the tote fluid lines32and injection lines33into the expanding additive area3is controlled by flow-control valves24which are in turn controlled by the controller21through control lines23. At this point, the additives are not likely to be well blended or mixed with the incoming drilling fluid. The poorly blended mixture then flows into a blending area6of the conveyor pipe5. The blending area6has an even larger cross-sectional area which creates another pressure drop. The blending area6is provided with turbulence vanes7which interrupt any laminar flow and promote turbulent flow which mixes and blends the additives and the drilling fluid. The now well blended drilling fluid then flows into a collimator area8which creates a laminar flow in the blended drilling fluid by passing portions of the fluid through long smaller tubes or passageways. A “gattling gun” type of tube arrangement is appropriate. Taking care not to reintroduce turbulence, the cross-sectional diameter of the conveyor pipe5is reduced to that of the outlet9and the pipe connected to the outlet for direct delivery of a laminar flow of blended drilling fluid to the high pressure pump which injects the blended drilling fluid into the well. Because the blended drilling fluid discharged from the outlet9is completely blended and is in laminar flow without turbulence, no further processing or handling of the outflow, and no further blending or settling of turbulence in a holding tank is necessary, and would instead be detrimental. The blended drilling fluid is provided to the high-pressure injection pump in a laminar flow at a steady moderate pressure. In the embodiment ofFIG.1, the blended drilling fluid flows from the outlet9into a holding tank41, for later use by the coiled-tubing operation. Referring toFIG.2, in the illustrated embodiment drilling fluid and the separate additives at the proper determined flow rate are conveyed separately from the chemical addition unit50to a mixing tank42, for mixing, and then to downstream end of the coiled-tubing operation. Many other changes and modifications can be made in the system and method of the present invention without departing from the spirit thereof. I therefore pray that my rights to the present invention be limited only by the scope of the appended claims. | 8,107 |
11859456 | DETAILED DESCRIPTION In the following detailed description of embodiments of the disclosure, numerous specific details are set forth in order to provide a more thorough understanding of the disclosure. However, it will be apparent to one of ordinary skill in the art that the disclosure may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description. Throughout the application, ordinal numbers (e.g., first, second, third, etc.) may be used as an adjective for an element (i.e., any noun in the application). The use of ordinal numbers is not to imply or create any particular ordering of the elements nor to limit any element to being only a single element unless expressly disclosed, such as using the terms “before”, “after”, “single”, and other such terminology. Rather, the use of ordinal numbers is to distinguish between the elements. By way of an example, a first element is distinct from a second element, and the first element may encompass more than one element and succeed (or precede) the second element in an ordering of elements. Embodiments disclosed herein relate to performing logging while having the logging tool levitating in a cased wellbore. The objective of embodiments disclosed herein is to introduce a simpler and a cost effective solution to replace complex hardware required for horizontal and extended reach drilling well conveyance while improving sensor position in the wellbore. The solution discussed herein is tailored for both tethered and untethered conveyance options, and applies to surface pipelines and cased-hole wells with ferromagnetic pipes. FIG.1illustrates an exemplary well (100) in accordance with one or more embodiments. As shown inFIG.1, a well path (110) may be drilled by a drill bit (112) attached by a drill string (104) to a drill rig (102) located on the surface of the earth (106). The well may traverse a plurality of overburden layers (108) and one or more cap-rock layers (114) to a hydrocarbon reservoir (116). The well path (110) may be a curved well path, or a straight well path. In one or more embodiments, the well path (110) may be described as vertical, deviated, horizontal, or extended reach drilling (ERD). One skilled in the art will be aware that deviated, horizontal, and ERD wells are considered to be complex. In one or more embodiments, logging, with the aid of conveyance methods, may be performed in the exemplary well (100). Typical logging operations are conducted during open hole drilling operations or if the well has open hole completion. However, logging may also occur in cased-hole wells, particularly in the production and intervention stages. For example, logging for the purpose of cement evaluation is conducted in a cased-hole environment. Further, some open hole wells also have cased-hole sections. The purpose of conveyance methods is to provide a safe and efficient way to take logging and intervention tools to a target depth, which, in some embodiments, may be a total depth. References to total depth herein may refer to the depth at which drilling is stopped, and therefore the depth of the bottom of the wellbore. For vertical wells, it is straightforward to use any type of line as a conveyance method. For example, a line may refer to wireline, slickline, or fiberline. However, the definition herein of a line is not meant to be limiting and a line may refer to any method of mechanically or electrically connecting a logging apparatus to the surface equipment of a well. As well complexity increases, the required equipment and procedure for conveyance becomes inherently more costly and complicated, with two particular challenges being lock-depth due to high drag and friction, and sensor position that is biased by the weight of the tools and conveyance system. Embodiments disclosed herein provide for a solution for logging operations in complex wells where both challenges are addressed and overcome simultaneously. FIGS.2A-2Dshow a variety of well orientations which may be drilled in one or more embodiments, and which may be integrated with a tethered conveyance method or an untethered conveyance method (not pictured). As noted above, tethered conveyance refers to all methods that provide direct mechanical and/or electrical connection to the logging and intervention tools. For example, a wireline conveyance provides both mechanical and electrical connection with logging tools, on the other hand, memory logging with through bit or coiled tubing provides only mechanical connection to the logging tools. The untethered conveyance refers to the use of sensors mounted on autonomous robots (i.e., single use/deployment sensors or self-deployed sensors) where no physical connection with the surface is present. Turning first toFIG.2A,FIG.2Ashows a casing (202), set in a vertical wellbore (204). In one or more embodiments, a logging while levitating (LWL) assembly (208) is shown connected to the drill rig (102) by a tether (206) and acts as a conveyance method for one or more logging tools. One skilled in the art would readily appreciate that there are many different types of logging tools which may be required for various operations. For example, an ultrasonic transducer may be required for corrosion inspection and cement evaluation. Further embodiments of the present disclosure may integrate with a tubing cutter or a power centralizer. Any suitable type of logging tool may be utilized with the LWL assembly (208) without departing from the scope of this disclosure. In one or more embodiments, a levitation force (210) may be applied to the LWL assembly (208) to eliminate contact of the assembly with the wellbore (204), wherein the LWL assembly is considered to ‘levitate’ in the center of the wellbore (204) or as close to the center as possible. The assembly is said to levitate because it is contactlessly deployed in the center of a cased wellbore.FIG.2Bshows the LWL assembly (208) disposed within a deviated wellbore (212). It will be known to one skilled in the art that a deviated wellbore (212) is one which is typically intentionally drilled away from vertical.FIG.2Cdepicts the LWL assembly (208) disposed within a horizontal wellbore (214).FIG.2Dshows the LWL assembly (208) disposed within an extended reach drilling (ERD) wellbore (216). It will be apparent to one skilled in the art that an ERD wellbore (216) extends further horizontally than it does vertically. AlthoughFIGS.2A-2Dillustrate specific well orientations, embodiments of the present disclosure may be implemented in a variety of well orientations without sacrificing functionality or performance. Standard conveyance methods may be integrated with a tethered LWL assembly (208). In vertical wellbores (204), the tether (206) may be a wireline, or any other type of line typically used to connect downhole tools to the surface equipment. In deviated wellbores (212) or horizontal wellbores (214), the tether (206) may comprise drill pipe and coil tubing. In ERD wellbores (216), the tether may comprise a combination of wireline, tractors, and wheeled carriages. In tethered conveyance methods, one or more embodiments of the present disclosure eliminate drag and friction on the logging tools and accessories by providing a levitation force (210) that will lift or push the LWL assembly (208) and any attached logging tools into the center of the wellbore (204) or as close to the center of the wellbore as possible. Ideally, the logging tool center is pushed to the well center or as close to the well center as possible. In some embodiments, pushing the logging tool center may involve lifting or elevating the tool center, especially for deviated and horizontal well sections. In some embodiments, it may not be required to elevate the whole tool string. In such embodiments, mechanical decoupling is required to isolate the section of the wellbore (204) where the LWL assembly (208) will be utilized. Mechanical decoupling may be achieved in a number of different ways. For example, the use of knuckle joints or flexible joints between tool string sections may allow for mechanical decoupling. This may permit selective levitation for specific sections of a tool string as needed or planned. In some embodiments, there may be one levitation force (210) applied to the LWL assembly (208) in order to maintain its central location in the wellbore (204). There may also be some embodiments wherein more than one levitation force (210) is applied to the LWL assembly (208) in order to maintain its central location in the wellbore (204). FIGS.3A-3Cshow examples of a LWL assembly (208) that is used to facilitate contactless deployment of tethered sensors in a vertical wellbore (204). More specifically,FIG.3Ashows an example of a LWL assembly (208), which comprises an electromagnet (310) connected to a tool body (302). Some embodiments may have one or more tilt sensors (306) mounted upon the electromagnet (310), though there may be embodiments that do not include tilt sensors (306). One or more proximity sensors (308) may be attached to the electromagnet (310). In embodiments where the LWL assembly (208) possesses more than one proximity sensor (308), a tilt sensor (306) may be optional. A levitation force (210) may be produced as a result of the interaction of the electromagnet (310) with a ferromagnetic casing (314), which may be disposed within the wellbore (204). In some embodiments, there may be two electromagnets (310) attached to a tool body (302) to produce two levitation forces (210) that act to center the LWL assembly (208) in the wellbore (204). FIG.3Bdepicts the versatility of the LWL assembly (208) in terms of how such an assembly may be positioned relative to a tool body (302). In one or more embodiments, the LWL assembly (208) may be an intra-body assembly (316), wherein the components of the LWL assembly (208) are included within the tool body (302). In other embodiments, the LWL assembly (208) may be an inter-body assembly (318), wherein the components of the LWL assembly (208) are embedded into the tool body (302), such that one part of the LWL assembly (208) is located on the interior of the tool body (302) and another part of the LWL assembly (208) is located exterior to the tool body (302). In further embodiments, the LWL assembly (208) may be an over-body assembly (320), wherein the LWL assembly (208) may be fitted around the tool body (302), such that an interior surface of the electromagnet (312) is flush with the exterior surface of the tool body (304), as shown in the example ofFIG.3A. In one or more embodiments, any of the intra-body assembly (316), inter-body assembly (318), or over-body assembly (320) may be employed where there are two electromagnets (310), complete with attached sensors, which may include tilt sensors (306) and/or proximity sensors (308). In these cases, the electromagnets (310) are positioned in a parallel fashion about a tool center (311), and the interior surfaces of the electromagnets (312) are flush with the exterior surfaces of the tool body (304). Further, additional tool accessories may be combined with the tool body (302) and the LWL assembly (208), forming a LWL apparatus (326), of which one embodiment is shown inFIG.3C. In some embodiments, such a combination may be an assembled over-body tool (322), where an over-body LWL assembly (320) is attached to the tool body (302) in conjunction with an accessory, of which there are many embodiments, to optimally achieve logging. Alternatively, in one or more embodiments, the LWL assembly may be a standalone LWL sub without any accessories or tools attached or integrated therein (seeFIG.6below). More specifically,FIG.3Cshows a LWL assembly (208) which is integrated with a standoff (324). A standoff (324) is a type of tool accessory which may be attached to the tool body (302). One skilled in the art will readily appreciate that there are many types of tool accessories, and all such accessories may be integrated with the LWL assembly (208) without departing from the scope of this disclosure. In some embodiments, it may be desirable to use an accessory which utilizes electromagnetic sensors to complete logging. In such embodiments, an accessory shield (not pictured) may be connected to the LWL apparatus (326) to avoid causing interference via the use of the electromagnet (310) and ferromagnetic casing (314). Turning now toFIGS.4A-4C,FIGS.4A-4Cshow examples of the implementation of a LWL assembly (208) in complex well orientations, including deviated wellbores (212), horizontal wellbores (214), and ERD wellbores (216). Similar toFIG.3A,FIG.4Ashows a LWL assembly (208) integrated with a tool body (302). Converse to embodiments which are suited to vertical wellbores (204), embodiments intended for use in complex wellbores require only one electromagnet (310) for producing a sufficient levitation force (210) to allow a logging tool to traverse contactlessly within the wellbore casing. One or more proximity sensors (308) may be mounted on the electromagnet (310). In some embodiments, a tilt sensor (306) may also be fixed to the electromagnet (310). Like in embodiments implemented in vertical wellbores (204), embodiments intended for use in complex wellbores may have integrated orienting accessories for optimal levitation.FIG.4Billustrates a LWL assembly (208) which is integrated with an orienting wheel (402). The orienting wheel (402) is configured to orient the LWL assembly so that it stays as close to the center of the casing as possible and in order to guide the LWL assembly in traversing the wellbore to a predetermined or particular depth. In one or more embodiments, the wheel may be rounded or round shaped. The orienting wheel (402) may have at least two wheels which are connected to a housing via an axle, which may systematically push down the center of gravity of the LWL assembly (208) and tool string. The orienting wheel (402) may force the tool string to face a certain direction regardless of its initial position and movement. In some embodiments, the number of orienting wheels (402) and their respective location along the tool string may be optimized based on tool string configuration and downhole conditions. In embodiments where the LWL assembly (208) possesses more than one proximity sensor (308), tilt sensors (306) and orienting wheels (402) may be optional. FIG.4Cdepicts the versatility of the LWL assembly (208) in terms of how such an assembly may be positioned relative to a tool body (302) in complex well profiles. The positioning of the LWL assembly (208) does not change between vertical wellbores (204) and complex wellbores. Therefore,FIG.4Cmay be considered to be analogous toFIG.3B. Depending upon the needs of the desired logging operation, an intra-body assembly (404), inter-body assembly (406), or over-body assembly (408) may be used. Similar to use of an LWL assembly (208) in vertical wells, the LWL assembly (208) may be combined with an accessory in one or more embodiments. For example, an assembled over-body tool (410) may be created when an over-body LWL assembly (408) is attached to the tool body (302) in conjunction with an accessory. For example, in one or more embodiments, an orienting wheel (402) may be combined with a LWL assembly (208) and a tool body (302) to form a LWL apparatus (412). In some embodiments, it may be desirable to use an accessory which utilizes electromagnetic sensors to complete logging. In such embodiments, an accessory shield (not pictured) may be connected to a LWL apparatus (412) to avoid causing interference via the use of the electromagnet (310) and ferromagnetic casing (314). FIG.5depicts an LWL apparatus (412) in an operative state in accordance with one or more embodiments. Embodiments of the present disclosure may be implemented in order to effectively levitate a downhole logging tool such that a tool center (506) is aligned with a well center (502). As shown inFIG.5, eccentricity (504) refers to the distance between the tool center (506) and the well center (502). A successful implementation of a LWL assembly (208) eliminates the eccentricity (504) via the application of a levitation force (210), which acts to counteract a gravitational force (510). The gravitational force (510) may be produced by a combination of the weight of the LWL assembly (208) and the weight of any tools and accessories needed for logging operations. Elimination of eccentricity (504) may also eliminate contact between the LWL assembly and any accompanying tools or accessories with the ferromagnetic casing (314). Hence, a resultant frictional force (508) is reduced to fluid friction only when the LWL assembly (208) is operational. A running-in-hole force (512) acts in opposition to the resultant frictional force (508). A successful deployment of a LWL assembly (208) requires satisfying a number of critical conditions. First, once well deviation exceeds a certain angle, the orientation of the LWL assembly (208) and any attached tools must be controlled and maintained in a specific direction. Controlling and maintaining a tool string in a specific direction, for example sensor side down, may allow the tool string to rotate such that it is forced in a given and constant direction. In some embodiments, this condition may be satisfied by offsetting the center of gravity of the tools. A levitation force may be oriented in opposition to weight and frictional forces, and the angle at which this is achieved may depend on well orientation. The angle may be determined during pre-job planning based on operation objectives and, as such, there is no minimum or maximum angle. In other embodiments, orienting accessories, such as an orienting wheel (402), may be attached to the LWL assembly (208). Second, the levitation force (210), which may also be referred to as an electromagnetic force, must be automatically activated or deactivated in order to properly accomplish levitation. Such control of the levitation force may occur at the surface in some embodiments, or downhole in other embodiments. Third, the required levitation force may be calculated based on the weight of the LWL assembly and any accompanying tools, eccentricity, and buoyancy. Fourth, a proximity sensor (308), which monitors the distance between the proximity sensor (308) and the ferromagnetic casing (314), may be used to determine the position of the LWL assembly (208) within the wellbore and to control the levitation force (210). FIG.6Adepicts a standalone LWL sub (602) integrated with a tool string (604). In addition to embodiments where the LWL assembly (208) is integrated with tools and accessories, there may be embodiments where a standalone LWL sub (602) is built and combined with any other tools to provide the same functionality as a LWL assembly (208) with higher levitation forces (210) and a modular configuration. In some embodiments, the standalone LWL sub (602) may refer to a combination of an electromagnet (310) and various sensors, which may include a tilt sensor (306) and/or a proximity sensor (308). In other embodiments, there may be additional tools or accessories combined with the electromagnet (310) and sensors. The standalone LWL sub (602) may be attached to a series of connected tool bodies (302), which may be referred to as a tool string (604). The standalone LWL subs (602) may be attached to each end of the tool string (604), or to other critical locations along the tool string (604). Levitation forces (210) may be applied to counteract the gravitational force (510). The use of standalone LWL subs (602) add flexibility and modularity to the tool string (604) and provide levitation to the entire tool string (604) in specific and critical locations along the tool string (604). Commonly used accessories to offset or centralize tools in horizontal wellbores (214) are shown inFIGS.6B-6E.FIG.6Billustrates an over-body centralizer, which may be implemented over a tool body (302) to offset the tool body from the wall of the wellbore (214), which may be ferromagnetic casing (314). Likewise, an inline centralizer, as shown inFIG.6C, may be implemented over a tool body (302) to offset the tool body from the wall of the wellbore (214).FIGS.6D and6Edepict the use of a standoff (324) or an orienting wheel (402) without a LWL assembly (208) in attempts to centralize the tool string (604). While the techniques depicted inFIGS.6B-6Edo reduce surface contact area with the wellbore (214), there is still some contact and therefore drag and friction still exists. Conversely, the implementation of a LWL assembly (208) or a standalone LWL sub (602) achieves perfect centralization within the wellbore, eliminates drag and friction, and also allows for contactless deployment. Implementation of a LWL assembly (208) or a standalone LWL sub (602) may lower chocks, vibrations, and tool wear and tear. FIG.7shows a flowchart for a method of logging while levitating in accordance with one or more embodiments. More specifically,FIG.7depicts a method (700) for levitating a LWL assembly (208) and maintaining the LWL assembly's position in the center of a casing (202).FIG.7may apply to both tethered and untethered conveyance methods. Further, one or more blocks inFIG.7may be performed by one or more components as described inFIGS.1-6E. While the various blocks inFIG.7are presented and described sequentially, one of ordinary skill in the art will appreciate that some or all of the blocks may be executed in different orders, may be combined, may be omitted, and some or all of the blocks may be executed in parallel. Furthermore, the blocks may be performed actively or passively. Initially, well data is provided as input data to configure a bottomhole hole assembly (BHA) according to the input data (S702). For example, the well data may be input into a software program. The software program may be any simulation program executing on a computing device (e.g., computer, tablet, smart phone, gaming device, etc.) with a processor and memory (not shown), located on the surface, that is capable of selecting/designing a BHA based on well data. As used herein, the term well data may refer to information regarding the well's deviation, depth, borehole fluid density, pressure, temperature, and diameter (internal profile). While these properties are some examples of well data and the definition used herein, this list is not exhaustive and is not intended to be limiting. The scope of the definition of well data encompasses any information which describes the well, wellbore, or formation. In one or more embodiments, a LWL assembly (208) type may be selected based on well orientation and the desired downhole logging tool (S704). In some embodiments, depending on the well data collected, it may be beneficial to select a LWL assembly (208) that is standalone, where the LWL assembly (208) is modified in order to add functionality of a desired downhole logging tool. In other embodiments, an integrated LWL assembly (208) may be desirable, wherein integrated refers to the combination of the LWL assembly (208) and a desired downhole logging tool. In further embodiments, an over-body LWL assembly (208) may be selected, wherein the LWL assembly (208) is fitted over the desired downhole logging tool. In S706, a LWL assembly (208) may be attached to a bottomhole assembly. Attachment of the LWL assembly (208) to the bottomhole assembly may depend on the situation. For example, attachment may differ depending on if the LWL assembly (208) is mounted directly onto to the tool string or if an accessory is added to the tool string. The bottomhole assembly may be any type of bottomhole assembly utilized within well drilling without departing from the scope of this disclosure. Depending upon well orientation, a determination is made to as to whether a vertical section LWL assembly (208) is required (S708). If a vertical section LWL assembly (208) is required (YES), a double face or multiple face LWL assembly (208) is used, and a start deviation is set to 0° (S710). Start deviation may refer to the deviation value at which the LWL assembly (208) may be started/powered on. Due to predetermined knowledge or measurement of well profile, depth versus deviation, and azimuth, deviation may be used to control depth, and start deviation is dependent upon depth. A double face LWL assembly (208) may refer to a LWL assembly (208) which utilizes two levitation forces (210) to center the LWL assembly (208) within the wellbore (204). A multiple face LWL assembly (208) may refer to a LWL assembly (208) which utilizes a plurality of levitation forces (210) to center the LWL assembly (208) in the wellbore (204) and which may improve system stability. If a vertical section LWL assembly (208) is not required (NO), a standard LWL assembly (208) is used and a start deviation is set to a desired angle, selected based on the deviation of the wellbore (212,214, or216) (S712). In some embodiments, a simulation software for lock depth may determine the depth at which the tool string will stop moving due to friction and increased deviations. In other embodiments, the start deviation angle may refer to the depth of the top logging interval, which is the depth at which data acquisition should begin and at which tool string position is critical for data quality. In further embodiments, the start deviation angle may be any other angle corresponding to a depth where the logging operation is required to start. In one or more embodiments, one angle may be seen at multiple depths, in S-shaped wells, for example. In such embodiments, the start deviation angle must be used as a reference to depth, not as its absolute value. In general, start deviation angle may refer to a reference point in the well trajectory at which the LWL assembly (208) is required to power on, and this point may be determined in any number of ways. Examples of methods of determining this reference point are measured depth, true vertical depth, deviation angle, and azimuth angle. However, this list is not exhaustive, and there may be other methods of determining this reference point which do not depart from the scope of this disclosure. The LWL assembly (208) may be run into the wellbore (204) to a start depth, which may be selected based on user objectives, desired downhole logging tools, well conditions, or any other factor related to the goal of the downhole logging endeavor (S714). Once the desired start depth has been reached, the LWL assembly (208) may be activated and the LWL assembly (208) position in the wellbore (204) may be read (S716). Activation refers to the process by which the levitation of the LWL assembly is triggered. When the LWL assembly (208) is activated, it may begin levitating the tool string off the wellbore side to as close as possible to the center of the wellbore. In one or more embodiments, activation may be achieved by sending power from the surface to switch on the LWL assembly (208). In these embodiments, an operator may monitor tool string position from the surface and determine when to activate the LWL assembly (208) to ensure tool string position is as close to centered in the wellbore as possible. In other embodiments, a command may be sent from the surface to internal electronics to power on the LWL assembly (208). In further embodiments, parameters may be predefined in order for the LWL assembly to self-power from the surface or autonomously from an internal battery. In one or more embodiments, activation of the LWL assembly (208) may be triggered by a downhole condition. For example, in one or more embodiments, a particular depth, deviation, pressure, and/or temperature may trigger the activation of the LWL assembly (208). In other embodiments, a reading from a tilt sensor (306), or a reading deviation from other sensors present in the BHA, may trigger the activation of the LWL assembly (208). The LWL assembly may be supplied with power from the surface (106) in some embodiments, or from a downhole battery in other embodiments. Once activated, the LWL assembly (208), via sensors, may determine if it is centered in the wellbore (204) (S718). For example, sensors may measure the eccentricity (504) or another distance to determine whether the LWL assembly is centered within the casing. If the LWL assembly (208) is not centered in the wellbore (204) (NO), the levitation force (210) may be adjusted in order to lift the LWL assembly (208) into the center of the wellbore (204) (S720). If the LWL assembly is centered (YES), then the process moves to S722. There are many methods of determining and controlling tool position within the wellbore (204). In one or more embodiments, an intermittent magnetization force, controlled based on electromagnetic field strength, may be utilized to control tool position. Tool position may be based on the angle of the LWL assembly (208) and the distance from the LWL assembly (208) to the inner wall of the ferromagnetic casing (314). These parameters may be fixed or adjustable. In embodiments wherein fixed parameters are utilized, LWL assemblies (208) are preset to provide a fixed force, wherein a combination of a number of such forces produces the required levitation force (210). In embodiments where adjustable parameters are utilized, the angle and distance from the LWL assembly to the inner wall of the ferromagnetic casing (314) are continuously monitored to allow for instant and live adjustment of force. In some embodiments, this adjustment may be made manually. In other embodiments, this adjustment may be made using a software program. If the LWL assembly (208) is centered in the wellbore (204), it is necessary to determine if a target depth has been reached (S722). In some embodiments, a target depth may refer to a total depth, located at the bottom or end of the wellbore (204) or at the end of the cased part of the wellbore. In other embodiments, a target depth may refer to a location within the wellbore where logging is desirable due to well conditions or other factors. If the target depth has not yet been reached, the LWL assembly (208) may continue to monitor its location within the wellbore (204) (S718), adjusting the levitation force (210) as required to maintain its central location within the wellbore while traversing the wellbore (204) (S720). Once the target depth has been reached, the LWL assembly (208) may facilitate logging while levitating in the center of the wellbore (204) at the target depth (S724). In one or more embodiments, levitation may be achieved either actively or passively. For active levitation, controllable and adjustable forces are used as levitation forces (210). In one or more embodiments, an electromagnetic force may be used in this manner. For passive levitation, a permanent and predesigned force may be applied, with the source of such a force being mounted on the LWL assembly. In one or more embodiments, such a permanent force may be produced by permanent magnets installed on the LWL assembly (208). In such embodiments, the LWL assembly may be considered to be active at all times as the permanent magnets provide a lifting force opposite to the weight of the tool string and friction. As described above, embodiments of the LWL assembly utilize both tethered conveyance and untethered conveyance.FIGS.8A and8Billustrate examples of an untethered LWL assembly (806) in accordance with one or more embodiments. An untethered LWL assembly (806) may be, for example, an autonomous robot that is sent downhole and which is not physically connected to the surface. Turning first toFIG.8A,FIG.8Ashows a tool body (804) upon which various other components are mounted to make up an untethered LWL assembly (806). One or more proximity sensors (308) may be disposed on a tool body (804), wherein the proximity sensors (308) may be positioned on opposite ends of the tool body (804). One or more tilt sensors (306) may also be disposed upon the tool body (804), with one tilt sensor (306) disposed at the center of the tool body (804). An orienting weight (808) may be disposed along an edge of the tool body (804) and may be removable. In one or more embodiments, once the untethered LWL assembly (806) has reached a target depth, the orienting weight (808) may be detached from the tool body (804), allowing the tool body (804) and attached sensors to float through the wellbore fluid (802) back to the surface (106) due to a density difference. Detachment of the orienting weight (808) may be controlled from the surface, autonomously, or a combination of both. In some embodiments, controlling detachment from the surface may refer to sending a pressure pulse, chemical, or surface command through the wellbore, for example. An electromagnet (310) may also be mounted on the tool body (804). Though untethered LWL assemblies (806) may be used in any well orientation, including complex well orientations, retrieval of the autonomous device may depend upon the complexity of the well trajectory and available solutions. In one or more embodiments, the electromagnet (310) may interact with the ferromagnetic casing (314) to create a levitation force (210), as shown inFIG.8B, which illustrates a longitudinal section view of the untethered LWL assembly (806). The levitation force (210) counters the gravitational force (510) in order to levitate or push the untethered LWL assembly (806) as close to the center of the wellbore as possible. Similarly, the running-in-hole force (512) may act in opposition to the resultant frictional force (510). In one or more embodiments, there may be an absence of ferromagnetic casing (314). In such embodiments, ferromagnetic casing (314) may be replaced by non-magnetic tubing, fiber-glass tubing, coated tubing, non-metallic tubing, or any other type of tubing or downhole environment which does not interact with the electromagnet (310). In these embodiments, the levitation force (210) may be provided by any contactless technique. For example, in some embodiments, thrusters may be used for dynamic positioning. In other embodiments, dynamic positioning may be achieved via the use of powered propellers. Any method of contactless dynamic position may be used without departing from the scope of this disclosure. Embodiments of the present disclosure may provide at least one of the following advantages. Logging and intervention in complex well profiles present many challenges for conveyance and data quality. Traditional pipe conveyed logging (PCL) or coiled tubing (CT) are prohibitive in terms of rig time, operational complexity and cost. Alternatively, tractor conveyance is limited by the available force in long laterals. Tools and accessories may create higher friction and may jeopardize tool position in the horizontal section. Consequently, both data quality and reaching total depth may be compromised. New techniques to reduce friction and optimize sensor position in the well were introduced recently using wheeled carriages, however these techniques do not completely eliminate friction or perfectly center the tool within the wellbore. Embodiments of the present disclosure introduce a novel deployment technique that eliminates friction, enables both tethered and untethered conveyance in complex well profiles using free fall forces, and provides a solution for shallow lock depth, which is a result of high drag and friction of logging and intervention tools due to contact with the production tubing or casing inner wall. Additionally, due to the lack of friction as a result of the use of embodiments of the present disclosure, conveyance reach is improved, allowing for additional depth to be achieved during logging operations. Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. § 112(f) for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function. | 37,061 |
11859457 | DETAILED DESCRIPTION FIGS.1-5are schematic diagrams of an example implementation of a wellbore intervention system100that includes one or more whipstocks126a-126bduring one or more intervention operations according to the present disclosure. Generally,FIGS.1-5illustrate wellbore intervention system100that includes aspects of wellbore construction and well completion accessories that allow rigless (for example, intervention without a drilling or workover rig) and through-tubing intervention operations into multiple laterals of a multilateral wellbore. In some aspects, wellbore intervention system100simplifies well completion methodologies while increasing monitoring and control of segments inside laterals of a multilateral wellbore. As described in more detail here, the wellbore intervention system100includes one or more whipstocks126aand126b; in alternative implementations, wellbore intervention system100can include a single whipstock or more than two whipstocks according to the present disclosure. The illustrated whipstocks126aand126bcan include orientation profiles (for example, one or more keys) that match or fit within orientation profiles (for example, one or more keyholes) that are run as part of a casing (or other wellbore tubular, such as a liner) and cemented in place in the wellbore. Further, the illustrated whipstocks126aand126bcan each include a bypass port with an opening on a whipstock face to allow a tool string (for example, with a smaller outer diameter (OD) than a diameter of the bore) to pass through to a next whipstock. In some example implementations, the wellbore intervention system100can include a temporary (for example, retrievable) plug that can be installed in a bypass port of a whipstock to close the bypass port and allow intervention into a lateral wellbore at the whipstock. In some aspects, the plug can also act as a pressure sealing element for pressure isolation (for example, fluid decoupling) between laterals. Thus, the example implementations of the whipstocks126a-126bcan be used for selective access different laterals for intervention operations, while also allowing selective production from one, some, or all of the laterals in a multilateral well. As illustrated, wellbore intervention system100includes a wellbore102formed from a terranean surface104into and through one or more subterranean formations103for the purpose of producing hydrocarbon fluids (for example, oil, gas, or both) or other fluids. In this example implementation, the wellbore intervention system100is a rigless system that includes a wellhead106at the terranean surface104to allow access to the wellbore102. Although labeled as a terranean surface104, this surface may be any appropriate surface on Earth (or other planet) from which drilling and completion equipment may be staged to recover hydrocarbons from a subterranean zone. For example, in some aspects, the surface104may represent a body of water, such as a sea, gulf, ocean, lake, or otherwise. In some aspects, all are part of the wellbore intervention system100may be staged on the body of water or on a floor of the body of water (for example, ocean or gulf floor). Thus, references to terranean surface104includes reference to bodies of water, terranean surfaces under bodies of water, as well as land locations. Although illustrated as generally vertical portions and generally horizontal portions, such parts of the wellbore102may deviate from exactly vertical and exactly horizontal (for example, relative to the terranean surface104) depending on the formation techniques of the particular wellbore102, type of rock formation in the subterranean formation103, and other factors. Generally, the present disclosure contemplates all conventional and novel techniques for forming the wellbore102from the surface104into the subterranean formation103. In this example, wellbore102includes a casing108that is secured (for example, cemented) in place in the wellbore102and extends from at or near the terranean surface104to at least a depth in which casing shoes120are installed. Although illustrated as a single casing108, casing108can be comprised of multiple casings that, as depth increases, decrease in diameter. For example, casing108can include a surface casing, a conductor casing, an intermediate casing, and a production casing (or a combination of less than these casings). For simplicity, the combination of casings can be referred to as casing108. At or near the casing shoes120are positioned liner hangers122from which a wellbore liner124can be hung and extend into a horizontal118of the wellbore102. In some examples, the liner124can also be secured (for example, cemented) into place in the wellbore102. As shown in this example, horizontal118extends from a curved or transition portion107of the wellbore102, which in turn extends from a vertical or near vertical portion of the wellbore102. As shown in this example implementation, a tubular (tubular string)110, such as a production tubing110, extends from at or near the terranean surface104into the wellbore102. In this example, the production tubing110terminates uphole of the lateral114a. One or more wellbore seals112(such as packers or other seals) are positioned in an annulus of the wellbore between the production tubing110and the casing108. The one or more wellbore seals112, once positioned and, in some cases, expanded to contact the tubing110and the casing108, can fluidly decouple a portion of the annulus of the wellbore102that is downhole from the wellbore seal(s)112from a portion of the annulus of the wellbore102that is uphole from the wellbore seal(s)112. Thus, any production fluid from the laterals114aand114band the horizontal118can be circulated (for example, forcibly or naturally) uphole to the terranean surface104through the production tubing110. Furthermore, as described in more detail here, one or more intervention tools (for example, positioned on a workstring such as regular or coiled tubing) can be run into the wellbore102through the production tubing110to selectively perform intervention operations in the laterals114aand114band the horizontal118based on operation of the whipstocks126aand126b. As illustrated in this example, laterals (or lateral wellbores)114aand114bextend (for example, horizontally or curved or slanted) from the wellbore102. Although two laterals114aand114b, the present disclosure contemplates that fewer or more laterals can be formed from the wellbore102. As shown, lateral114aextends from the wellbore102at lateral casing window116a, while lateral114bextends from the wellbore102at lateral casing window116b. Thus, in this example, three lateral wellbores—lateral114a, lateral114b, and horizontal118—are shown. Components such as casings, liners, sleeves, inflow control devices, and other production control equipment can be placed in one, some, or all of the illustrated lateral wellbores. As shown inFIG.1, wellbore intervention system100includes whipstock126athat, in this figure, is run into the wellbore102and secured to the casing108in a particular orientation. As shown, whipstock126aincludes a body128athat can be generally cylindrical and has an uphole axial surface130a, a downhole axial surface140a, and a radial exterior surface131a. In this example, the radial exterior surface131aincludes a profile134a(also called keys134a) that can be secured in corresponding keyholes136athat are formed (for example, machined) in the inner surface of the casing108. When the keys134amate with the keyholes136a, the whipstock126ais positioned adjacent and just downhole of the lateral casing window116a. As shown in this example, the uphole axial surface130ais angled or slanted from a first edge portion of a top circumference to a second edge portion that is approximately 180° radially apart from the first edge portion. Thus, as shown, when the keys134amate with the keyholes136a, the whipstock126ais positioned such that the uphole axial surface130ais angled downward toward the lateral casing window116a(in other words, the first edge portion is slightly more uphole than the second edge portion). As shown inFIG.1, the whipstock126aincludes a bore132a(for example, a cylindrical bore) that extends from the uphole axial surface130ato the downhole axial surface140a, thereby creating a flowpath through the whipstock126a. As described in more detail herein, the bore132acan be used as a flowpath for production fluids, a pass through for an intervention tool, or both, as needed. In some aspects, and as shown in this example implementation, the whipstock126acan include one or more magnets138athat are positioned adjacent or near the bore132ain the body128aof the whipstock126a. In some aspects, the magnets138a(which can be permanent magnets, electromagnets, or other type of magnets) can attract a bottom hole assembly of an intervention tool to guide the tool through the bore132a(when running into the wellbore102to, for example, the lateral114b). In further aspects, and as shown in this example implementation, the whipstock126acan include a sensor142athat is positioned adjacent or near the bore132ain the body128aof the whipstock126a. In some aspects, the sensor142acan detect (and send a signal to terranean surface104based on the detection) a presence of a bottom hole assembly of an intervention tool to guide the tool through the bore132a(when running into the wellbore102to, for example, the lateral114b). In still further aspects, and as shown in this example implementation, the whipstock126acan include one or more magnets144athat are positioned adjacent or near the uphole axial surface130aof the body128aand, more particularly, near an uphole edge (in other words, the first edge portion) of the slanted surface130aand away from the lateral casing window116a. In some aspects, the magnets144a(which can be permanent magnets, electromagnets, or other type of magnets) can attract a bottom hole assembly of an intervention tool to guide the tool through the bore132a(when running into the wellbore102to, for example, the lateral114b). As also shown inFIG.1, wellbore intervention system100also includes whipstock126bthat, in this figure, is run into the wellbore102and secured to the casing108in a particular orientation. As shown, whipstock126bincludes a body128bthat can be generally cylindrical and has an uphole axial surface130b, a downhole axial surface140b, and a radial exterior surface131b. In this example, the radial exterior surface131bincludes a profile134b(also called keys134b) that can be secured in corresponding keyholes136bthat are formed (for example, machined) in the inner surface of the casing108. When the keys134bmate with the keyholes136b, the whipstock126bis positioned adjacent and just downhole of the lateral casing window116b. In some aspects, the keys134aof the whipstock126awould not fit into the keyholes136band, vice versa, the keys134bof the whipstock126bwould not fit into the keyholes136a. As shown in this example, the uphole axial surface130bis angled or slanted from a first edge portion of a top circumference to a second edge portion that is approximately 180° radially apart from the first edge portion (as with the uphole axial surface130aof whipstock126a). Thus, as shown, when the keys134bmate with the keyholes136b, the whipstock126bis positioned such that the uphole axial surface130bis angled downward toward the lateral casing window116b(in other words, the first edge portion is slightly more uphole than the second edge portion). As shown inFIG.1, the whipstock126bincludes a bore132b(for example, a cylindrical bore) that extends from the uphole axial surface130bto the downhole axial surface140b, thereby creating a flowpath through the whipstock126b. As described in more detail herein, the bore132bcan be used as a flowpath for production fluids, a pass through for an intervention tool, or both, as needed. In some aspects, the bore132aof the whipstock126ais larger (for example, in diameter) than the bore132bof the whipstock126b. In alternative aspects, the bore132aof the whipstock126ais substantially the same size (for example, in diameter) as the bore132bof the whipstock126b. In some aspects, and as shown in this example implementation, the whipstock126bcan include one or more magnets138bthat are positioned adjacent or near the bore132bin the body128bof the whipstock126b. In some aspects, the magnets138b(which can be permanent magnets, electromagnets, or other type of magnets) can attract a bottom hole assembly of an intervention tool to guide the tool through the bore132b(when running into the wellbore102to, for example, the horizontal118). In further aspects, and as shown in this example implementation, the whipstock126bcan include a sensor142bthat is positioned adjacent or near the bore132bin the body128bof the whipstock126b. In some aspects, the sensor142bcan detect (and send a signal to terranean surface104based on the detection) a presence of a bottom hole assembly of an intervention tool to guide the tool through the bore132b(when running into the wellbore102to, for example, the horizontal118). In still further aspects, and as shown in this example implementation, the whipstock126bcan include one or more magnets144athat are positioned adjacent or near the uphole axial surface130aof the body128aand, more particularly, near an uphole edge (in other words, the first edge portion) of the slanted surface130aand away from the lateral casing window116a. In some aspects, the magnets144a(which can be permanent magnets, electromagnets, or other type of magnets) can attract a bottom hole assembly of an intervention tool to guide the tool through the bore132a(when running into the wellbore102to, for example, the lateral114b). FIG.1shows an implementation of the wellbore intervention system100in which the whipstocks126aand126bhave been installed in the wellbore102but prior to an intervention operation being performed in one or more of the laterals114a-114bor horizontal118. In some aspects,FIG.1represents the wellbore intervention system100in which one, some, or all of the laterals114a-114band horizontal118are (or were) producing hydrocarbon (or other) fluids into the wellbore102, through the production tubing110, and to the terranean surface. In other aspects,FIG.1represents the wellbore intervention system100in which none of the laterals114a-114band horizontal118are (or have been) producing hydrocarbon (or other) fluids into the wellbore102, thus necessitating one or more intervention operations. In some aspects, the whipstocks126aand126bare permanent components of the construction of the wellbore intervention system100and, once installed in the casing108, completion components (for example, valves, open hole packers, inflow control devices, tracers) can be installed in the wellbore102, including the laterals114a-114band the horizontal118. Turning toFIG.2, this figure illustrates the wellbore intervention system100during an intervention operation into the lateral114aby an intervention tool201that includes a bottom hole assembly (BHA)202mounted on a workstring200. As shown, the intervention tool201can be run into the wellbore102and through the production tubing110to a location uphole of the whipstock126a(but downhole of the termination of the production tubing110). In this example, prior to running the intervention tool201into the wellbore102, a retrievable plug204can be set (for example, mechanically or otherwise) into the bore132ato seal the bore132a. As shown, in some aspects, a top of the plug204, once positioned in the bore132a, is angled similarly to the uphole axial surface130aof the body128a. Thus, when positioned in the bore132a, the plug204in combination with the uphole axial surface130acreates a solid, angled surface (in other words, with no hole created by the bore132a). In some aspects, complementary profiles on an outer surface of the plug204and the inner surface of the body128athat defines the bore132acan ensure that the plug204can be positioned correctly to create a flush surface with the uphole axial surface130a. In alternative aspects, the OD of BHA202may be bigger that the ID of the bore132a, such that the intervention tool201does not enter the bore and is pushed into lateral114a. In this alternative aspect, for example, a plug204may not be needed. When running the intervention tool201into the wellbore102subsequent to installation of the plug204into the bore132a, therefore, the whipstock126acan function as a conventional whipstock and guide the BHA202into the lateral114a. For instance, the BHA202may contact the uphole axial surface130a(with the plug204installed) and slide angularly toward the lateral casing window116ato enter the lateral114aas shown. Intervention operations can then be performed in the lateral114awith the intervention tool201. Subsequent to the intervention operations within the lateral114a, the intervention tool201can be run out of the wellbore102and the plug204removed (for example, by a wireline or tubing mounted tool) from the bore132a. In some aspects, production of hydrocarbon fluids can then commence (or re-commence) through the bore132a. Turning toFIG.3, this figure illustrates an operation of the wellbore intervention system100in which intervention operations may be required in the lateral114b(or horizontal118). Thus, the intervention tool201can pass through the bore132ato reach the lateral114b(or horizontal118). As shown, the BHA202may be sized to fit through the bore132a. In some aspects, entry of the BHA202into the bore132a(at the uphole axial surface130a) can be assisted by one or more features of the whipstock126a. For example, as shown with the dashed line representation of the BHA202, the one or more magnets144aof the whipstock126acan attract the BHA202toward an “uphole edge” of the angled surface of the uphole axial surface130a. As further weight is put on the intervention tool201(for example, by the workstring200), the BHA202can slide away from the uphole edge (and the one or more magnets144a) and into the bore132a. As another example component that can be used in addition or alternatively to the one or more magnets144a, an entry guide205can first be installed in the bore132a. In some aspects, the entry guide205can include a cone or funnel shape entry to guide (or help guide) the BHA202into the bore132a. In some aspects, once the BHA202has entered the bore132a(or to help guide the BHA202into the bore132a), the one or more magnets138apositioned adjacent the bore132acan attract the BHA202. In some aspects, the magnet(s)138acan pull or help pull the BHA202(and intervention tool201) into and through the bore132a. In some aspects, as the BHA202passes through the bore132a, the sensor142acan detect a presence of the BHA202(for example, magnetically, electrically, or otherwise). The detected presence of the BHA202passing through the bore132acan be transmitted (wired or wirelessly) from the sensor142ato the terranean surface104. Turning toFIG.4, this figure illustrates the wellbore intervention system100during an intervention operation into the lateral114bby the intervention tool201and BHA202subsequent to passing through the bore132aof the whipstock126a. In this example, prior to running the intervention tool201into the wellbore102, another retrievable plug204can be set (for example, mechanically or otherwise) into the bore132bto seal the bore132b. In some aspects, this operation can be performed with the BHA202. In an alternate aspect, the OD of BHA202may be bigger than the ID of the bore132band smaller than the bore132a, such that the intervention tool201will pass through upper whipstock126abut not enter the bore of126band, instead, can be pushed into lateral114b. This alternative aspect may not require the plug204to be installed in whipstock126b. As shown, in some aspects, a top of the plug204, once positioned in the bore132b, is angled similarly to the uphole axial surface130bof the body128b. Thus, when positioned in the bore132b, the plug204in combination with the uphole axial surface130bcreates a solid, angled surface (in other words, with no hole created by the bore132b). In some aspects, complementary profiles on an outer surface of the plug204and the inner surface of the body128bthat defines the bore132bcan ensure that the plug204can be positioned correctly to create a flush surface with the uphole axial surface130b. When running the intervention tool201into the wellbore102subsequent to installation of the plug204into the bore132b, therefore, the whipstock126acan function as a conventional whipstock and guide the BHA202into the lateral114b. For instance, the BHA202may contact the uphole axial surface130b(with the plug204installed) and slide angularly toward the lateral casing window116bto enter the lateral114bas shown. Intervention operations can then be performed in the lateral114bwith the intervention tool201. Subsequent to the intervention operations within the lateral114b, the intervention tool201can be run out of the wellbore102and the plug204removed (for example, by a wireline or tubing mounted tool) from the bore132b. In some aspects, production of hydrocarbon fluids can then commence (or re-commence) through the bore132b. Turning toFIG.5, this figure illustrates an operation of the wellbore intervention system100in which intervention operations may be required in the horizontal118. Thus, the intervention tool201can pass through the bores132aand132bto reach the horizontal118. As shown, the BHA202may be sized to fit through the bores132aand132b(whether they are the same or different diameters). In some aspects, entry of the BHA202into the bore132b(at the uphole axial surface130b) can be assisted by one or more features of the whipstock126b, similarly to the operation described inFIG.3for the whipstock126a. For example, the one or more magnets144bof the whipstock126bcan attract the BHA202toward an “uphole edge” of the angled surface of the uphole axial surface130b. As further weight is put on the intervention tool201(for example, by the workstring200), the BHA202can slide away from the uphole edge (and the one or more magnets144b) and into the bore132b. As another example component that can be used in addition or alternatively to the one or more magnets144a, an entry guide (such as entry guide205) can first be installed in the bore132b. In some aspects, the entry guide205can include a cone or funnel shape entry to guide (or help guide) the BHA202into the bore132b. In some aspects, once the BHA202has entered the bore132b(or to help guide the BHA202into the bore132b), the one or more magnets138bpositioned adjacent the bore132bcan attract the BHA202. In some aspects, the magnet(s)138bcan pull or help pull the BHA202(and intervention tool201) into and through the bore132b. In some aspects, as the BHA202passes through the bore132b, the sensor142bcan detect a presence of the BHA202(for example, magnetically, electrically, or otherwise). The detected presence of the BHA202passing through the bore132bcan be transmitted (wired or wirelessly) from the sensor142bto the terranean surface104. Subsequent to the intervention operations within the horizontal118, the intervention tool201can be run out of the wellbore102(and back through bores132band132a). In some aspects, production of hydrocarbon fluids can then commence (or re-commence) through the bores132band132afrom one, some, or all of the laterals114a-114band horizontal118. FIGS.6A-6Dshow an example implementation of a scope head600that can be used with a whipstock, such as one or both of the whipstocks126aand126b. In this example implementation, the scope head600is comprised of two or more scope arms605that are positioned on an uphole end of a body601of the scope head600through a bore610extends. In this example, the bore610extends from at or near an uphole opening620(that is adjustable by the arms605) to a downhole opening615. The scope head600, generally, can be run into a wellbore and positioned within at least a portion of a bore of a whipstock according to the present disclosure to selectively allow access through the bore (when the scope head600is in an open position) or deny access through the bore (when the scope head600is in a closed position). FIGS.6A-6Bshow the example implementation of the scope head600in an open position. In the open position, the arms605can be extended away from a centerline axis602of the scope head600to fluidly connect the uphole opening602with the bore610and with the downhole opening615. By fluidly connecting the uphole opening602with the bore610and with the downhole opening615, fluids or intervention tools can pass through the bore610of the scope head600. FIG.6Cshows the example implementation of the scope head600as it adjusts from the open position to a closed position. For example, a signal (wired or wireless) from the terranean surface can be provided to the scope head600to adjust the scope head600from the open position to a closed position and, vice versa, from the open position to a closed position. As shown inFIG.6C, the signal can operate to adjust the arms605toward the centerline axis602of the scope head600to reduce a size of the uphole opening620. FIG.6Dshows the example implementation of the scope head600in the closed position. In the closed position, the arms605are moved toward the centerline axis602of the scope head600to fluidly disconnect the uphole opening602with the bore610and with the downhole opening615(for example, by closing the uphole opening620). By fluidly disconnecting the uphole opening602with the bore610and with the downhole opening615, fluids or intervention tools cannot pass through the bore610of the scope head600. FIG.6Eshows an example implementation of an operation performed with the wellbore intervention system100that includes one or more whipstocks126a-126band the scope head600. This figure shows movement of the scope head600downhole through the wellbore102and, more specifically, through the production tubular110, the whipstock126a, and into the whipstock126b. For example, as shown, the scope head600can be run into the wellbore on a downhole conveyance650(such as a wireline or other conveyance). As the scope head600passes through the production tubular110, it can be in the closed position. In this example, the scope head600also remains in the closed position as it passes through the bore132aof the whipstock126a(on the downhole conveyance650, shown in dashed line between the production tubular110and the whipstock126a. In this example, the scope head600then is run into the bore132bof the whipstock126bwhere it can be adjusted to the open position (for example, by a signal through the downhole conveyance650). Thus, in this figure, the scope head600can allow an intervention tool to pass through the bore132band into the horizontal118. Alternatively, the scope head600can be positioned in the bore132band adjusted to (or remain in) the closed position to force an intervention tool to enter the lateral114b. As another example, the scope head600can be positioned in the bore132aand adjusted to (or remain in) the closed position to force an intervention tool to enter the lateral114a. In some aspects, use of the scope head600can replace, for example, a retrievable plug that can be positioned in one or both of the bores132a-132bof the respective whipstocks126a-126b. Further, in some aspects, the scope head600can be used in implementations of the wellbore intervention system100in which the bores132aand132bare the same or approximately the same size (for example, same diameter). While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any inventions or of what may be claimed, but rather as descriptions of features specific to particular implementations of particular inventions. Certain features that are described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination. Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described program components and systems can generally be integrated together in a single software product or packaged into multiple software products. A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. For example, example operations, methods, or processes described herein may include more steps or fewer steps than those described. Further, the steps in such example operations, methods, or processes may be performed in different successions than that described or illustrated in the figures. Accordingly, other implementations are within the scope of the following claims. | 29,943 |
11859458 | The illustrated figures are only exemplary and are not intended to assert or imply any limitation with regard to the environment, architecture, design, or process in which different embodiments may be implemented. DETAILED DESCRIPTION In the following detailed description of the illustrative embodiments, reference is made to the accompanying drawings that form a part hereof. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is understood that other embodiments may be utilized and that logical structural, mechanical, electrical, and chemical changes may be made without departing from the spirit or scope of the invention. To avoid detail not necessary to enable those skilled in the art to practice the embodiments described herein, the description may omit certain information known to those skilled in the art. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the illustrative embodiments is defined only by the appended claims. The present disclosure relates to dissolvable pump down devices, dissolvable pump down assemblies, and methods to propel a bottomhole assembly through a lateral section of a wellbore. The dissolvable pump down device includes an engageable portion and one or more expandable pieces. As referred to herein, an engageable portion is a portion that is configured to engage to another component, device, or apparatus, such as a wellbore isolation device, a bottomhole assembly, or another component, device, or apparatus. Further, as referred to herein, expandable pieces include any accessory, component, device, or apparatus that is initially in a first position, and configured to expand from the first position to a second position, where the diameter of the one or more expandable pieces while the expandable pieces are in the second position is greater than the diameter of the one or more expandable pieces while the expandable pieces are in a first position. Examples of expandable pieces include flanges, rings, blades, wings, and other accessories, components, devices, or apparatuses that are shiftable or expandable from a first position to a second position to increase the diameter of the expandable pieces. In some embodiments, where the engageable portion of the dissolvable pump down device is coupled to a bottomhole assembly, the diameter of the one or more expandable pieces is approximately equal to the outer diameter of the bottomhole assembly when the bottomhole assembly and the dissolvable pump down device are initially lowered into a vertical section of a wellbore. After the bottomhole assembly is lowered to a downhole location at or near the lateral section of the wellbore, fluid is injected into wellbore. A force applied by the fluid on the expandable pieces shifts or expands the expandable pieces from the first position to a second expanded position, such that the diameter of the expandable pieces increases while the expandable pieces are in the second position. In some embodiments, the expandable pieces expand radially outward toward the wall of the lateral section such that the diameter of the expandable pieces is greater than the outer diameter of the bottomhole assembly. The expansion of the expandable pieces increases the surface area of expandable pieces that come into contact with the fluid which, in turn, increases the force applied by the fluid onto the expandable pieces, and propels the dissolvable pump down device and the bottomhole assembly to a desired wellbore location, such as at or near a boundary of a zone of the wellbore. In some embodiments, the expandable pieces are configured to shift from the second position back to the first position if the force applied by the fluid is less than a threshold amount of force. In one or more of such embodiments, an operator controls the fluid flow of the fluid pumped downhole to propel the dissolvable pump down device to the desired location. The dissolvable pump down device and a wellbore isolation device form a dissolvable pump down assembly that is coupled to the bottomhole assembly. As referred to herein, a wellbore isolation device refers to any device or apparatus configured to form a seal to isolate a section of the wellbore. Examples of wellbore isolation devices include, but are not limited to, frac plugs, darts, balls, packers and other devices or apparatuses configured to form a seal to isolate a section of the wellbore. The dissolvable pump down assembly is detachably coupled to bottomhole assembly such that the dissolvable pump down assembly detaches from, disengages, breaks off, or shears off bottomhole assembly after the dissolvable pump down assembly is positioned at the desired wellbore location, thereby allowing the bottomhole assembly to be retracted uphole, fitted with a second, third, or additional dissolvable pump down assemblies to be deployed to other locations of the lateral section of the wellbore, such as at or near other boundaries of the lateral section. In some embodiments, the process described herein is repeated to deploy a desired number of dissolvable pump down assemblies to different locations of the lateral section to form multiple seals and isolate multiple zones of the lateral section. In some embodiments, the dissolvable pump down assembly also includes a dissolvable mule shoe that is coupled to the dissolvable pump down device, and/or other components that facilitate the deployment of the dissolvable pump down assembly, facilitate the expandable pieces to shift from the first position to the second position and from the second position to the first position, and facilitate the dissolvable pump down assembly to detach, disengage, break off, shear off, or decouple from the bottomhole assembly. The dissolvable pump down device is formed from a dissolvable material that dissolves after a period of time (such as a day, a week, a month, or another threshold of time) to reduce or eliminate the need to drill out the dissolvable pump down device. In some embodiments, the engageable portion and the expandable pieces are formed from different types of dissolvable materials and having different properties, and dissolve over different periods of time. In some embodiments, different components of the dissolvable pump down assembly are formed from different dissolvable materials. In some embodiments, some or all of the components of the dissolvable pump down assembly are formed from the same dissolvable material. Additional descriptions of the dissolvable pump down device, dissolvable pump down assembly, and methods to propel a bottomhole assembly through a lateral section of a wellbore are provided in the paragraphs below and are illustrated in at leastFIGS.1-5. Turning now to the figures,FIG.1is a schematic, side view of an environment100in which a bottomhole assembly112that is coupled to a dissolvable pump down assembly is lowered into a wellbore114via a wireline118. As shown inFIG.1, wellbore114has a vertical section115that extends from a wellhead106at a surface108downwards to a formation126, and a lateral section117that extends laterally or horizontally through formation126. A wireline vehicle150is positioned near wellhead106to deploy wireline118through a wellhead106into wellbore114. A lubricator is positioned above wellhead106to facilitate lowering wireline118down wellbore114and lifting wireline118up from wellhead106of a well102. In the embodiment ofFIG.1, bottomhole assembly112is coupled to a dissolvable pump down device160via an engageable portion of dissolvable pump down device160. Dissolvable pump down device160also has one or more expandable pieces that are initially in a first position prior to and during initial deployment of bottomhole assembly112. After bottomhole assembly112is lowered to a downhole location at or near lateral section117, a fluid is injected into wellbore114. In some embodiments, the fluid is injected from a fluid vehicle (not shown) that is positioned near wellhead106. As the fluid flows through wellbore114and around bottomhole assembly112, force applied by the fluid on the expandable pieces of dissolvable pump down device160shifts dissolvable pump down device160from the first position to a second expanded position, such that the diameter of the expandable pieces increases while the expandable pieces are in the second position. In some embodiments, the expandable pieces expand or bend radially outward toward the wall of lateral section117of wellbore114. The expansion of the expandable pieces increases the surface area of expandable pieces that come into contact with the fluid which, in turn, increases the force applied by the fluid onto the expandable pieces, and propels dissolvable pump down device160to a desired wellbore location, such as a location at or near dash line112A, which represents a first boundary of zone111A. In some embodiments, the expandable pieces shift from the first position to the second position in response to a threshold amount of force or pressure applied by the fluid, and shift from the second position to the first position if less than the threshold amount of force or pressure is applied by the fluid. In that regard, an operator controls the amount of distance dissolvable pump down device160travels along lateral section117by controlling the fluid that is pumped down wellbore114. A wellbore isolation device120that is coupled to bottomhole assembly112and/or dissolvable pump down device160is then set off or actuated at or near dash line112A to form a fluid seal at the first boundary of zone111A. Examples of wellbore isolation devices include, but are not limited to, frac plugs, packers, darts, balls, and other devices or components configured to form a fluid seal around a section of a wellbore. In the embodiment ofFIG.1, wellbore isolation device120and dissolvable pump down device160together form a dissolvable pump down assembly that is detachably coupled to bottomhole assembly112such that the dissolvable pump down assembly detaches from, breaks off, or shears off bottomhole assembly112after the dissolvable pump down assembly is positioned at the desired wellbore location, thereby allowing bottomhole assembly112to be retracted uphole, fitted with a second dissolvable pump down assembly having a second dissolvable pump down device (not shown) and a second wellbore isolation device (not shown). The process described herein is then repeated to lower bottomhole assembly112down vertical section115, flow fluid downhole to propel the second dissolvable pump down assembly to a second desired wellbore location at or near dash line112B, which represents a second boundary of zone111A. The second wellbore isolation device is set off and the second dissolvable pump down assembly detaches from, breaks off, or shears off bottomhole assembly112. In the embodiment ofFIG.1, the foregoing process is repeated to propel additional dissolvable pump down assemblies (not shown) to desired downhole locations at or near dash lines112C and112D, and additional wellbore isolation devices of the dissolvable pump down assemblies are set off or actuated to form zones111B and111C. In the embodiment ofFIG.1, each component of the dissolvable pump down assembly is formed from a dissolvable material. In some embodiments, dissolvable pump down device160and wellbore isolation device120are formed from different dissolvable materials. Additional descriptions and illustrations of dissolvable pump down device160and wellbore isolation device120are provided in the paragraphs below and are illustrated in at leastFIGS.2and3. AlthoughFIG.1illustrates four boundaries of three zones111A-111C, in some embodiments, the operations described herein are performed a different number of iterations to propel a different number of dissolvable pump down assemblies (not shown) downhole to set or form a different number of seals or boundaries. Further, althoughFIG.1illustrates on lateral section117, in some embodiments, multiple lateral sections are connected to vertical section115of wellbore114. Further, althoughFIG.1illustrates wireline118that is coupled to bottomhole assembly112, in some embodiments, another type of conveyance is coupled to bottomhole assembly112to deploy and retract bottomhole assembly112. Further, althoughFIG.1illustrates a cased wellbore, the dissolvable pump down device160illustrated inFIG.1, as well as other dissolvable pump down devices described herein, are deployable in open-hole wellbores, and cased wellbores and open-hole wellbores of offshore wells. FIG.2is a cross-sectional view of a dissolvable pump down assembly similar to the dissolvable pump down assembly ofFIG.1, and coupled to a bottomhole assembly212. In the embodiment ofFIG.2, the dissolvable pump down assembly includes a dissolvable pump down device260, a mule shoe222, and a wellbore isolation device220, each of which is formed from a dissolvable material that dissolves after a period of time. Dissolvable pump down device260has an engageable portion261that is coupled to a mandrel214(such as a tension mandrel) of bottomhole assembly212. In some embodiments, engageable portion261has a threaded interface that matches a corresponding threaded interface of mandrel214such that engageable portion261is screwed onto mandrel214to couple the dissolvable pump down assembly to bottomhole assembly212. In one or more of such embodiments, the frangibility of the threaded interface, the number of threads of the threaded interface, and the frangibility of the engageable portion determine a setting force (such as the force applied to shear mandrel214and bottomhole assembly212away from the dissolvable pump down assembly). In some embodiments, flanges262are formed from a plastic, a soft metal, a synthetic rubber, or any combination thereof. In some embodiments, mule shoe222also has a threaded interface for receiving a threaded interface of mandrel214. In one or more of such embodiments, a portion of mule shoe222is also configured to shear off mandrel214to detach bottomhole assembly212from the dissolvable pump down assembly. Dissolvable pump down device260also includes flanges262, which are in a first position as illustrated inFIG.2. More particularly, the initial outer diameter of flanges262are equal to or approximately equal to the outer diameter of wellbore isolation device220and bottomhole assembly212. Flanges262are configured to expand or shift outward, such as radially outward toward the wall of lateral section117in response to a threshold amount of force or pressure (such as force applied by a fluid pumped downhole into lateral section117) applied to flanges262, where the outer diameter of flanges262while flanges262are in the second position is greater than the outer diameter of flanges262while flanges262are in the first position as illustrated inFIG.2. In some embodiments, flanges262form a circular or semi-circular canopy similar to a canopy of an umbrella, where flanges262are initially in a folded position (first position), similar to a folded position of an umbrella. Further, the outer diameter of flanges262expands radially outward (similar to the outer diameter of the canopy of the umbrella) as flanges262shift from the first folded position to a second deployed position. In some embodiments, the outer diameter of flanges262while in the second position is equal to or approximately equal to the diameter of lateral section117. The expansion of flanges262increases the surface area of flanges262that come into contact with the fluid which, in turn, increases the force applied by the fluid onto flanges262, and propels dissolvable pump down device260, wellbore isolation device220, and bottomhole assembly212to a desired wellbore location, such as a location at or near a boundary of a zone of lateral section117. Wellbore isolation device220is then set or actuated to form a seal at or near the boundary of the zone. The dissolvable pump down assembly is configured to detach from, disengage, break off, or shear away from bottomhole assembly212after dissolvable pump down device260is propelled to the desired location, thereby allowing retrieval of bottomhole assembly212for further operations, including operations described herein to propel additional pump down devices to other desired locations at or near other boundaries of lateral section117or other lateral sections to form additional seals. In some embodiments, a portion of engageable portion261that is coupled to mandrel214detaches from, disengages, breaks off, or shears away from the rest of engageable portion261, thereby detaching bottomhole assembly212from the dissolvable pump down assembly. In some embodiments, engageable portion261is formed from a hardened plastic or metal that is brittle and designed to crack and break apart under stress due to a setting force. In some embodiments, flanges262are formed from a flexible material such as a synthetic rubber. In some embodiments, flanges262are formed from a sturdier material, such as plastic, a soft metal, or any combination thereof. In some embodiments, engageable portion261, flanges262, mule shoe222, and wellbore isolation device220are formed from different dissolvable materials that dissolve over different periods of time. In some embodiments, some of the components of the dissolvable pump down assembly are formed from materials that dissolve over similar or identical periods of time. AlthoughFIG.2illustrates flanges262, in some embodiments the dissolvable pump down assembly ofFIG.2includes blades, wings, rings, or other accessories or components that are configured to radially expand from a first position to a second position in response to a threshold amount of force applied to the blades, wings, rings, or other accessories or components. FIG.3is a cross-sectional view of a side and partially cross-sectional view of another dissolvable pump down assembly similar to the dissolvable pump down assembly ofFIG.1, and coupled to a bottomhole assembly (not shown and positioned uphole or to the left of the dissolvable pump down assembly illustrated inFIG.3). In the embodiment ofFIG.3, the dissolvable pump down assembly includes a dissolvable pump down device360, a mule shoe322, and a wellbore isolation device320, each of which is formed from a dissolvable material that dissolves after a period of time. Dissolvable pump down device360has an engageable portion362that is coupled or fitted into a groove of mule shoe322. In some embodiments, engageable portion362is fitted to (such as into a groove) or coupled to another component of the dissolvable pump down assembly. Dissolvable pump down device360also has an expandable piece361that is ring shaped and flexible at a connecting portion that connects expandable piece361to engageable portion362such that a threshold amount of pressure applied to expandable piece361shifts expandable piece361from the first position illustrated inFIG.3, where the diameter of expandable piece361is approximately equal to the outer diameter of wellbore isolation device320and the bottomhole assembly, to a second position, where the outer diameter of the expandable piece at the second position is greater than the outer diameter of the expandable piece in the first position and as illustrated inFIG.3. In some embodiments, expandable piece361forms a circular or semi-circular canopy similar to a canopy of an umbrella, where expandable piece361is initially in a folded position (first position), similar to a folded position of an umbrella. Further, the outer diameter of expandable piece361expands radially outward (similar to the outer diameter of the canopy of the umbrella) as expandable piece361bends or shifts from the first folded position to a second deployed position. The expansion of expandable piece361increases the surface area of expandable piece361that come into contact with the fluid which, in turn, increases the force applied by the fluid onto expandable piece361, and propels dissolvable pump down device360, wellbore isolation device320, and the bottomhole assembly to a desired wellbore location, such as a location at or near a boundary of a zone of lateral section117ofFIG.1. Wellbore isolation device320is then set or actuated to form a seal at or near the boundary of the zone. The dissolvable pump down assembly is configured to detach from, disengage, break off, or shear away from the bottomhole assembly after dissolvable pump down device360is propelled to the desired location, thereby allowing retrieval of the bottomhole assembly for further operations, including operations described herein to propel additional pump down devices to other desired locations at or near other boundaries of lateral section to form additional seals. In some embodiments, a threshold amount of force is applied to a shear pin (not shown) that is initially engaged to of the bottomhole assembly and a component of the dissolvable pump down assembly to shear the shear pin and detach or decouple the bottomhole assembly from the dissolvable pump down assembly. FIG.4is a flow chart of a process400to propel a bottomhole assembly through a lateral section of a wellbore. Although the operations in the process400are shown in a particular sequence, certain operations may be performed in different sequences or at the same time where feasible. At block S402, a dissolvable pump down device that is coupled to a bottomhole assembly is deployed into a wellbore. In that regard,FIG.1illustrates deployable pump down device160that is coupled to bottomhole assembly112and deployed in wellbore114.FIG.2illustrates a similar downhole device260and bottomhole assembly212deployed in lateral section117of wellbore114ofFIG.1. At block S404, a threshold amount of fluid force is applied to one or more expandable pieces of the dissolvable pump down device to expand the one or more pieces from a first position to a second position to increase the diameter of the expandable pieces. In the embodiment ofFIG.2, fluid pumped from a fluid source down wellbore114applies a threshold amount of force to flanges262ofFIG.2to expand flanges262from the initial position illustrated inFIG.2, where the outer diameter of flanges262is approximately equal to the outer diameter of wellbore isolation device220and bottomhole assemble212, to a second position, where the outer diameter of flanges262at the second position is greater than the outer diameter of flanges262at the first position. Similarly, in the embodiment ofFIG.3, fluid pumped from a fluid source down wellbore114applies a threshold amount of force to the ring shaped expandable piece361ofFIG.3to expand expandable piece361from the initial position illustrated inFIG.4, where the outer diameter of expandable piece361is approximately equal to the outer diameter of wellbore isolation device320and bottomhole assemble312, to a second position, where the outer diameter of expandable piece361at the second position is greater than the outer diameter of expandable piece361at the first position. Moreover, the expansion of the expandable pieces increases the surface area of expandable pieces that come into contact with the fluid which, in turn, increases the force applied by the fluid onto the expandable pieces. At block S406, the dissolvable pump down device is propelled to a desired location in a lateral section of a wellbore. In some embodiments, the threshold amount of force applied to the expandable pieces to propel the dissolvable pump down device is similar or identical to the threshold amount of force applied to the expandable pieces to shift or expand the expandable pieces from the first position to the second position. In some embodiments, the threshold amount of force applied to the expandable pieces to propel the dissolvable pump down device is greater than the threshold amount of force applied to the expandable pieces to shift or expand the expandable pieces from the first position to the second position. In some embodiments, the amount of force applied to the one or more expandable pieces varies (while being above the threshold amount) to control or vary the rate at which the dissolvable pump down device traverses the lateral section. In some embodiments, the expandable pieces shift from the second position to the first position if the amount of force applied to the expandable pieces is less than a threshold amount of force. In some embodiments, after the dissolvable pump down device is propelled to a desired location, such as at or near a wellbore boundary illustrated by line112A ofFIG.1, a wellbore isolation device (such as a frac plug) that is coupled to the dissolvable pump down device is actuated or set to form a fluid seal at or near the wellbore boundary. FIG.5is a flow chart of a process500to propel the bottomhole assembly ofFIG.4to multiple locations of the lateral section of the wellbore. Although the operations in the process500are shown in a particular sequence, certain operations may be performed in different sequences or at the same time where feasible. Operations performed at blocks S402, S404, and S406are described in the paragraphs above. At block S408, the dissolvable pump down device is disengaged, decoupled, or sheared from the bottomhole assembly. In the embodiment ofFIG.2, a portion of engageable portion261that is coupled to mandrel214of bottomhole assembly212shears off or breaks off from the rest of engageable portion261which, in turn, disengages bottomhole assembly212from the dissolvable pump down assembly. At block S410, the bottomhole assembly is retrieved, such as retrieved to surface108ofFIG.1. At block S412, a determination on whether to deploy another dissolvable pump down device into the wellbore, such as wellbore114ofFIG.1is made. The process ends if no additional dissolvable pump down device is deployed into the wellbore. Alternatively, the process proceeds to block S414if a determination to deploy another dissolvable pump down device is made. At block S414a second dissolvable pump down device is coupled to the bottomhole assembly, such as bottomhole assembly112ofFIG.1. At block S416, the second dissolvable pump down device and the bottomhole assembly are deployed into the wellbore, such as wellbore114ofFIG.1. The process then proceeds to block S404, and operations performed at blocks S404, S406, S408, and S410are performed to propel the second dissolvable pump down device to a desired wellbore location, such as a second boundary defined by dash lines112B ofFIG.1, disengage the bottomhole assembly from the second dissolvable pump down device, and retrieve the bottomhole assembly for deployment of additional dissolvable pump down devices or other operations. The above-disclosed embodiments have been presented for purposes of illustration and to enable one of ordinary skill in the art to practice the disclosure, but the disclosure is not intended to be exhaustive or limited to the forms disclosed. Many insubstantial modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure. For instance, although the flowcharts depict a serial process, some of the steps/processes may be performed in parallel or out of sequence, or combined into a single step/process. The scope of the claims is intended to broadly cover the disclosed embodiments and any such modification. Further, the following clauses represent additional embodiments of the disclosure and should be considered within the scope of the disclosure. Clause 1, a dissolvable pump down device comprising: an engageable portion; and one or more expandable pieces, each of the one or more expandable pieces initially being in a first position before the dissolvable pump down device is deployed in a wellbore, and each of the one or more expandable pieces configured to expand from the first position to a second position in response to a force generated by fluid flow of a fluid through the wellbore, wherein a diameter of the one or more expandable pieces while the one or more expandable pieces are in the first position is less than the diameter of the one or more expandable pieces while the one or more expandable pieces are in the second position, and wherein the engageable portion and the one or more expandable pieces are configured to dissolve after the dissolvable pump down device is positioned at the desired wellbore location. Clause 2, the dissolvable pump down device of clause 1, wherein the one or more expandable pieces are configured to propel the dissolvable pump down device to the desired wellbore location while the one or more expandable pieces are in the second position. Clause 3, the dissolvable pump down device of clauses 1 or 2, wherein the one or more expandable pieces are configured to shift from the second position towards the first position after the dissolvable pump down device is positioned at the desired downhole location. Clause 4, the dissolvable pump down device of clause 3, wherein the one or more expandable pieces are configured to shift from the second position towards the first position if the force generated by the fluid flow of the fluid onto the one or more expandable pieces is less than a threshold amount of force. Clause 5, the dissolvable pump down device of any of clauses 1-4, wherein after the one or more expandable pieces expand to the second position, the diameter of the one or more expandable pieces is greater than a diameter of a bottomhole assembly that is coupled to the dissolvable pump down device. Clause 6, the dissolvable pump down device of any of clauses 1-5, wherein the one or more expandable pieces are flanges, and wherein each of the one or more flanges is configured to expand from the first position to the second position. Clause 7, the dissolvable pump down device of any of clauses 1-5, wherein the one or more expandable pieces are rings, and wherein each of the one or more rings is configured to expand from the first position to the second position. Clause 8, the dissolvable pump down device of any of clauses 1-7, wherein the engageable portion is configured to engage to a mandrel of a bottomhole assembly, and wherein the engageable portion is configured to shear off the mandrel after the dissolvable pump down device is positioned at the desired downhole location. Clause 9, the dissolvable pump down device of any of clauses 1-8, wherein the engageable portion is coupled to a wellbore isolation device that is configured to form a seal after the dissolvable pump down device is positioned at the desired downhole location. Clause 10, the dissolvable pump down device of clause 9, wherein the dissolvable pump down device is coupled to a mule shoe, and wherein the wellbore isolation device and the mule shoe are formed from dissolvable materials. Clause 11, the dissolvable pump down device of any of clauses 1-10, wherein the one or more expandable pieces are formed from a first dissolvable material that dissolves at a first rate, and wherein the engageable portion is formed from a second dissolvable material that dissolves at a second rate. Clause 12, a dissolvable pump down assembly comprising: a wellbore isolation device configured to set at a desired wellbore location to form a fluid seal; and a dissolvable pump down device comprising: an engageable portion; and one or more expandable pieces, each of the one or more expandable pieces initially being in a first position before the dissolvable pump down device is deployed in a wellbore, and each of the one or more expandable pieces configured to expand from the first position to a second position in response to a force generated by fluid flow of a fluid through the wellbore, wherein a diameter of the one or more expandable pieces while the one or more expandable pieces are in the first position is less than the diameter of the one or more expandable pieces while the one or more expandable pieces are in the second position, and wherein the engageable portion and the one or more expandable pieces are configured to dissolve after the dissolvable pump down device is positioned at the desired wellbore location. Clause 13, the dissolvable pump down assembly of clause 12, wherein the one or more expandable pieces are configured to propel the dissolvable pump down device to the desired wellbore location while the one or more expandable pieces are in the second position. Clause 14, the dissolvable pump down assembly of clause 13, wherein the one or more expandable pieces are configured to shift from the second position towards the first position after the dissolvable pump down device is positioned at the desired downhole location. Clause 15, the dissolvable pump down assembly of clause 14, wherein the one or more expandable pieces are configured to shift from the second position towards the first position if the force generated by the fluid flow of the fluid onto the one or more expandable pieces is less than a threshold amount of force. Clause 16, the dissolvable pump down assembly of any of clauses 12-15, further comprising a mule shoe, wherein the wellbore isolation device and the mule shoe are formed from dissolvable materials. Clause 17, the dissolvable pump down assembly of any of clauses 12-16, wherein the wellbore isolation device is one of a frac plug, a dart, or a ball. Clause 18, a method to deploy a bottomhole assembly through a lateral section of a wellbore, comprising: deploying a dissolvable pump down device that is coupled to a bottomhole assembly into a wellbore, the dissolvable pump down device comprising: an engageable portion; and one or more expandable pieces, each of the one or more expandable pieces initially being in a first position before the dissolvable pump down device is deployed in a wellbore; applying a threshold amount of fluid force to the one or more expandable pieces to expand the one or more expandable pieces from the first position to a second position, wherein a diameter of the one or more expandable pieces while the one or more expandable pieces are in the first position is less than the diameter of the one or more expandable pieces while the one or more expandable pieces are in the second position; and propelling the dissolvable pump down device to a desired location in a lateral section of the wellbore. Clause 19, the method of clause 18, further comprising after the dissolvable pump down device is propelled to the desired location, actuating a wellbore isolation device that is coupled to the dissolvable pump down device to form a fluid seal. Clause 20, the method of clauses 18 or 19, wherein the engageable portion is initially coupled to the bottomhole assembly, the method further comprising after the dissolvable pump down device is propelled to the desired location: disengaging the bottomhole assembly from the dissolvable pump down device; and dissolving the dissolvable pump down device. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprise” and/or “comprising,” when used in this specification and/or in the claims, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. In addition, the steps and components described in the above embodiments and figures are merely illustrative and do not imply that any particular step or component is a requirement of a claimed embodiment. | 35,799 |
11859459 | DETAILED DESCRIPTION All the figures are highly schematic and not necessarily to scale, and they show only those parts which are necessary in order to elucidate the invention, other parts being omitted or merely suggested. FIG.1shows a downhole tool1for removing a restriction2, as shown inFIG.2, in a well tubular metal structure3. The well tubular metal structure3inFIG.2has a wall4and an inner diameter ID. The restriction may be a ball valve, as shown inFIGS.2and3, being partially closed and thereby partly blocking the inner diameter, creating an opening5defined at least partly by a rim section6of the restriction. The downhole tool1shown inFIG.1comprises a tool axis L and a tool body7having a first part17and a second part18. The downhole tool1further comprises an electrical motor8arranged in the first part for rotating a rotatable shaft9and a core bit10arranged in the second part and having a first end11connected with the rotatable shaft and a second end12having a cutting edge14for cutting into the restriction. The second part18of the downhole tool further comprises a locator15for locating the rim section and a collecting means16(shown inFIG.5) for collecting a cut-out part36of the restriction2after being cut out by the cutting edge14. The locator15and the collecting means16are rotating with the core bit10until the locator locates the rim section and a threshold value is reached. By having the locator and the collecting means rotating with the core bit until the locator locates the rim section and a threshold value is reached, the locator can enter the opening, and the collecting means can fasten the cut-out part of the restriction so that the cut-out part is brought to surface along with the tool after the operation has ended. The cut-out part may obstruct the well tubular metal structure, and it is therefore important that it is removed along with the tool and does not remain in the well. Thus, the downhole tool is able to cut out the part of the valve restricting access and retrieve part of the half-closed valve from the well to regain access to the well below the valve. As shown inFIG.5, the core bit has a centre axis L2, and the locator15has a locator axis L3which is arranged radially offset from the centre axis. The locator15rotates with the core bit, and both the core bit10and the locator15are forced forward towards the restriction in the well while rotating. When the locator hits against the rim section6, the locator is prevented from further rotation, and as the core bit keeps rotating the threshold value is reached, and the locator stops rotating and is disconnected from the rotating core bit. The primary function of the locator is to guide the collecting means16into the opening so that the cut-out part of the restriction is fastened between the collecting means16and the core bit, and so that the cut-out part of the restriction can be retrieved from the well. By having the locator arranged radially offset from the centre axis, the locator is able to locate the opening of the half-closed valve and thus guide the collection means into the opening in order to be able to retrieve the cut-out part of the restriction. The opening of a partly closed valve often does not overlap the centre of the core bit, and by arranging the locator off-centre from the centre of the core bit, the locator is thus able to locate the rim section of the opening. The same applies when the locator is arranged off-centre from the centre axis, or when the locator has a locator axis which is arranged at a distance in a radial direction away from the centre axis. The locator has a first locator end28connected with the core bit and a second locator end29having a tapering shape. When the second locator end29of the locator15hits against the rim section6(shown inFIG.3), the locator is prevented from further rotation, and as the core bit keeps rotating the threshold value is reached, and the locator stops rotating and is disconnected from the rotating core bit. The cutting edge14of the core bit is provided by bits or inserts30which cut into the restriction until a cut-out part36of the restriction is cut free from the remaining part37of the restriction. The locator enters the opening5(shown inFIG.3) and is forced further into the opening while cutting, and the collecting means16is also forced into the opening so that the collecting means is squeezed into the opening between the rim section and the core bit. Thus, by having the locator arranged radially offset from the centre axis, the downhole tool is able to cut out part of the restriction and bring the cut-out part to surface along with the tool, even though the valve is only half-closed. The locator15and the collecting means16arranged within the core bit10are fixedly connected inFIG.5. The second part18comprises a base part19, and the locator and the base part are also fixedly connected so that when the locator stops rotating, the base part also stops rotating. The core bit comprises a ball bearing21arranged between the core bit10and the base part19. The core bit is connected with the locator by means of a fastening means22, such as a coupling23(shown inFIG.5), a shear part24(shown inFIG.9) or a spring-loaded pin25(shown inFIG.6), until the threshold value is reached. The coupling may be a friction coupling or a torque coupling, the coupling being arranged between the base part and the core bit. Thus, the fastening means is arranged between the base part and the core bit. As shown inFIG.6, the core bit has an indentation39for receiving the spring-loaded pin25. The core bit10ofFIG.6is not rotationally symmetric around the axis L. InFIG.8, the second part18comprises the base part19and a spring20. The spring20is arranged between the locator15and the base part19so that the locator is allowed to move along the tool axis towards the first end of the core bit if the locator reaches the restriction before rotating further on to the opening. The locator then compresses the spring when the locator rotates as it reaches the restriction, but only until the locator hits against the rim section and is forced into the opening. The spring has an extension L4along the tool axis L so as to spring-load the locator if the locator does not reach the opening when rotating while moving along the tool axis but reaches a part of the restriction. When the locator rotates and is forced axially along the tool axis, the locator then reaches the level of the restriction, and when moving further along the tool axis, the spring is compressed. If the locator does not enter the opening directly, the locator is then able to move towards the first end11, compressing the spring20, and when rotating further when reaching the opening, the locator moves into the opening, stopping its further rotation, and the threshold is reached, disconnecting the locator from the core bit. The sudden stop activates the deactivation of the fastening means22, e.g. the shear pin inFIG.9is broken, and the core bit continues rotating. The indentation39engages with the spring-loaded pin25inFIG.6until the threshold is reached, and the pin is then forced out of the indentation39, and the spring20forces the locator to be slightly offset along the tool axis so that the pin25is no longer able to engage the indentation. The core bit10has a centre axis L2coincident with the tool axis L, as shown inFIG.5, and the collecting means is arranged radially offset from the centre axis so that the collecting means is able to enter the opening which is created by the half-closed valve and which is also offset of the tool axis. InFIG.6, the collecting means comprises a plurality of bendable parts26for engaging the cut-out part36(illustrated inFIG.5) of the restriction. The bendable parts extend radially from the locator in the form of arms. The bendable parts26are shaped as flexible fingers which are more flexible than the locator so that when the locator extends into the opening, the bendable parts26bend to fit into the opening. By having the collecting means comprising a plurality of bendable parts, the collecting means are able to fit a variety of openings and when operating in an oil well where visibility is low and it may be difficult to measure the exact geometry of the opening. The bendable parts may be plate-shaped radially extending fingers of some type of spring steel as shown inFIG.9, and distance elements53are arranged in between the plate-shaped radially extending fingers26A (shown inFIG.7). The collecting means16extends radially from the locator15as shown inFIGS.5and9and has a radial extension R1being larger than that of the opening. InFIG.5, the collecting means comprises at least one projectable part27for being projected when having passed the opening for supporting the cut-out part of the restriction so as to hold the cut-out part36of the restriction in place between the core bit10and the projectable part. The projectable part27may be spring-loaded in order to project underneath the cut-out part of the restriction. The collecting means16may extend radially all the way around the locator15as shown inFIG.9where the extension of the bendable parts/arms26vary so that the arms are longer towards the centre axis of the tool than opposite the core bit. InFIG.10, the collecting means16extends only partly around the locator as the collecting means16extends primarily from the locator towards the centre axis of the tool. As shown inFIGS.5and6, the locator15projects from the cutting edge14along the tool axis L. In this way, the locator hits the restriction first when the second part of the tool moves along the tool axis towards the restriction. In another embodiment, the second locator end29of the locator has a tapering shape so as to guide the locator into the opening. The collecting means16could thus also be this tapering-shaped end as this end could be squeezed in between the rim section and the core bit as the core bit moves and cuts further into the restriction. The spring between the base part and the locator is thus designed to be able to be compressed accordingly so that the core bit is able to keep moving and rotating until the restriction is fully cut, separating the cut-out part36. When rotating, the core bit10cuts out a part of the restriction which occupies the space within the core bit, and the cut-out part prevents fluid within the core bit from escaping from the second end12of the core bit10, and as the cut-out part moves towards the first end11, it may displace the fluid within the space and out through apertures45in the first end11, as shown inFIG.6. InFIG.1, the downhole tool1further comprises a gearing section31connected between the electrical motor and the rotatable shaft9for reducing the rotation of the core bit in relation to a rotational output shaft9B of the motor. The downhole tool1further comprises an axial force generator33providing an axial force along the tool axis while rotating the core bit10. The axial force generator is arranged in the first part17for moving the second part18in relation to the first part along the tool axis L. In order to transfer all the rotation of the motor to the core bit, the downhole tool1further comprises an anchoring tool section32for preventing the tool from rotating within the casing. The anchoring tool section comprises projectable anchoring elements. InFIG.4, the downhole tool1comprises a driving unit34, such as a downhole tractor, for preventing the tool from rotating within the casing and for providing an axial force along the tool axis. Thus, no axial force generator or anchoring section is needed. The tool ofFIG.4has two driving sections which are 90 degrees displaced along the circumference of the tool. As can be seen inFIGS.1and4, the downhole tool may be a wireline tool in which a wireline43is connected to an electronic control unit40for powering the motor8. The wireline may also power a second motor41driving a pump42for providing hydraulic power to drive the anchoring section32and the axial force generator33ofFIG.1, or the driving unit34ofFIG.4. Thus, the driving unit34comprises the second motor41driving the pump42for rotating wheels51and projecting arms52onto which the wheels are arranged until the wheels abut the inner face of the well tubular metal structure. The downhole tool may also comprise a compensator44for providing a surplus pressure inside the downhole line separation tool, as shown inFIG.4. In another embodiment, the downhole tool may also comprise a second pump and an accumulating section for suction of shavings from the cutting process and into the accumulating section through the apertures45(shown inFIG.6). An axial force generator may be a stroking tool and is a tool providing an axial force. The stroking tool comprises an electrical motor for driving a pump. The pump pumps fluid into a piston housing to move a piston acting therein. The piston is arranged on the stroker shaft. The pump may pump fluid into the piston housing on one side and simultaneously suck fluid out on the other side of the piston. By “fluid” or “well fluid” is meant any kind of fluid that may be present in oil or gas wells downhole, such as natural gas, oil, oil mud, crude oil, water, etc. By “gas” is meant any kind of gas composition present in a well, completion or open hole, and by “oil” is meant any kind of oil composition, such as crude oil, an oil-containing fluid, etc. Gas, oil and water fluids may thus all comprise other elements or substances than gas, oil and/or water, respectively. By “casing” or “well tubular metal structure” is meant any kind of pipe, tubing, tubular, liner, string, etc., used downhole in relation to oil or natural gas production. In the event that the tool is not submergible all the way into the casing (by gravity), a driving unit such as a downhole tractor can be used to push the tool all the way into position in the well. The downhole tractor may have projectable arms having wheels, wherein the wheels contact the inner surface of the casing for propelling the tractor and the tool forward in the casing. A downhole tractor is any kind of driving tool capable of pushing or pulling tools in a well downhole, such as a Well Tractor®. Although the invention has been described above in connection with preferred embodiments of the invention, it will be evident to a person skilled in the art that several modifications are conceivable without departing from the invention as defined by the following claims. | 14,546 |
11859460 | It should be understood that the drawings are not necessarily to scale and that the disclosed embodiments are sometimes illustrated diagrammatical and in partial views. In certain instances, details which are not necessary for an understanding of this disclosure or which render other details difficult to perceive may have been omitted. It should be understood, of course, that this disclosure is not limited to the particular embodiments illustrated herein. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be understood by reference to the following detailed description, which should be read in conjunction with the appended drawings. It is to be appreciated that the following detailed description of various embodiments is by way of example only and is not meant to limit, in any way, the scope of the present invention. Turning now toFIG.1, a description concerning the various components of the present invention will now be briefly discussed. As can be seen in this embodiment, the present invention relates to two fitting/assemblies—a first lower assembly1and a second upper assembly2which, when assembled with one another as discussed below in further detail, form a fluid connection of a pressurizable assembly PA (seeFIGS.8and13, for example). The first lower assembly1has a tubular section4which supports one or more elastomeric seals21which will form a seal with a mating tubular section of the second upper assembly2once the upper and lower assemblies1,2properly engage with one another, as discussed below in further detail. The first lower assembly1has a conventional lower connection member5which facilitates connection of the first lower assembly1to the wellhead in a conventional manner as well as a plurality or series of spaced apart cam grooves3formed in an exterior surface the first lower assembly1. The lower connection member5has a central opening O1formed therein which permits a fluid to flow into and out of the first lower assembly1. It is to be appreciated that the lower connection member5can incorporate different types of connections to allow the first lower assembly1to be affixed to the wellhead but is shown here as a conventional flange for illustrative purposes only. The second upper assembly2has a hollow housing6which has an internal diameter which is size and shaped to intimately receive and mate with the tubular section4of the first lower assembly1. As shown inFIG.3, the hollow housing6has a tapered section (not numbered) which reduces the diameter of the hollow housing6. This taper assists with properly aligning the tubular section4of the first lower assembly1with the reduced diameter section of the second upper assembly2so as to achieve a fluid tight seal therebetween with the assistance of the elastomeric seals21(seeFIG.3). In addition, the second upper assembly2has a plurality or series of radially mounted locking pin mechanisms7, e.g., four equally spaced apart locking pin mechanisms, and a conventional upper connection member8which facilitates connection of the second upper assembly2to a desired piece of pressure equipment. The upper connection member8has a central opening O2formed therein which permits a fluid to flow into and out of the second upper assembly2and communicate with the tubular section4. As with the first lower assembly1, the upper connection member8, supported at the top of the second upper assembly2, can have a variety of different designs such as (but not limited to) a flange, a quick union, or some other threaded union. However, for illustrative purposes, a flange is depicted in this figure. Once the first lower assembly1is properly connected to the second upper assembly2, a desired fluid passageway (shown by double arrow P inFIG.3) is formed by the pressurizable assembly PA which permits a fluid, e.g., water, liquid or gas, to flow between the desired piece of pressure equipment and the wellhead, as is conventional in the art. FIG.2is an exploded view of the locking pin mechanism7which comprises a locking pin9, a compression spring10and a pin housing11which accommodates those components. As shown, a rear surface of the pin housing11has a through bore extending therethrough which accommodates a trailing end of the respective locking pin9. The assembly housing6has a mating through bore (not shown in detail) though which the leading end of each locking pin9projects while an associated collar, of each locking pin9, is larger in diameter than the diameter of the respective through bore, in the assembly housing6, so as to prevent the locking pin9from passing completely therethough. When the respective locking pin9is inserted through the respective through bore of the assembly housing6and the trailing end of the locking pin9is accommodated by pin housing11with the spring10in a compressed state located between the pin housing11and the collar of the locking pin9, the spring10generates a force which pushes the locking pin9radially inward toward a longitudinal central axis CA defined by the pressurizable assembly C. As shown, a plurality of bolts22(e.g., four bolts) secure each pin housing11to the exterior surface of the assembly housing6of the second upper assembly2. The spring10functions to constantly and continuously urge the locking pin9radially inward toward the central axis CA of the pressurizable assembly PA. Turning now toFIG.3, once the upper and lower assemblies1,2are properly fitted together, a fluid tight seal is formed therebetween due to the close tolerance fit between the tubular section4and the reduced diameter section of the hollow housing6and the elastomeric seals21. In this Figure, the elastomeric seals comprise two O-rings12with a circular cross-section. However there are alternate designs that could be utilized to achieve the desired seal and still fall within the spirit and scope of the present invention. In the depicted embodiment, the first lower assembly1would be attached to the wellhead and the second upper assembly2would be attached to the pressure control equipment or some other equipment desired to be attached to the wellhead. The pressure control equipment or other equipment, in turn, would be attached to a conventional crane or hoisting device to facilitate the desired vertically upward and downward movement of the second upper assembly2relative to the first lower assembly1, as discussed below in further detail. When the crane or hoisting device lowers the second upper assembly2onto and into engagement with the first lower assembly1, the two assemblies1,2, engage with one another and create a fluid tight seal for the flow passage P. The achieved fluid tight seal of the pressurizable assembly PA is not limited to but is generally assumed to be suitable for a working pressure of 10 ksi or greater. FIG.4A through4Cillustrate the interaction between the locking pin9(only one of which is shown in these figures) and a respective cam groove3as the crane lowers the second upper assembly2(which may be attached to the pressure control equipment) onto the first lower assembly1(which may be attached to the wellhead). In order to clearly visualize the inner workings of the locking mechanism, the remaining components of the second upper assembly2, are removed and only a single one of locking pins9is shown.FIGS.4A-4Cshow how locking pin9, which is constantly being forced radially inward by the respective spring10, is gradually directed toward and enters through the entrance EN of the respective cam groove3as the crane lowers the second upper assembly2toward the first lower assembly1. FIG.5shows a detailed view of the uppermost portion of each respective cam groove3and a clearer view of how the shape and surface profile of the second upper assembly2assists with guiding each one of the locking pins9toward the entrance EN of the respective cam grooves3as the second upper assembly2is lowered into engagement with the first lower assembly1. As stated above, the spring10constantly forces the locking pin9radially inward toward the central axis A. The inwardly facing surface of the locking pin9is forced against the outer generally cylindrical surface24of the first lower assembly1, as generally shown inFIG.4A. As second upper assembly2is lowered toward the first lower assembly1, the cylindrical surface24and the pair of V-shaped pin guide surfaces23and25assist with directing and channeling the locking pin9toward the entrance EN of the respective cam groove3(seeFIG.5). After the pair of V-shaped pin guiding surfaces23and25directed the locking pin9into the entrance EN of the respective cam groove3, the locking pin then follows along the first cam segment13of the cam groove3as the second upper assembly2is lowered into engagement with the first lower assembly1.FIGS.4A-4Cthe sequence of positions that the locking pin9follows while moving along the first cam segment14before eventually reaching the end of the first cam segment13. Turning now toFIG.6, a first step13is located at a transition between the end of the first cam segment14and the beginning of the second cam segment15. That is, the end of the first cam segment13is located slightly further away from the central axis CA than the beginning to the second cam segment15so that the first step13, e.g., a radially inward step of between 1/16 to 1 inch or so and more preferably a step of about ½ of an inch, is formed between the end of the first cam segment14and beginning of the second cam segment15. Since the locking pin9, which is constantly forced radially inward, as the locking pin9passes or transitions from the end of the first cam segment13to the beginning of the second cam segment15, the locking pin9passes over the first step13. Once the locking pin9is completely located within the beginning of the second cam segment15, the spring10forces the locking pin9radially inward a small distance, e.g., the thickness or height of the first step13. As a result of this, the first step13now prevents the locking pin9from again following along the first cam segment14of the cam groove3. As such, the first step13functions to prevent the respective locking pin9from retracing its path upward along the first cam segment14of the cam groove3. Accordingly, when the crane again exerts a lifting force of the second assembly3, the locking pin9will thus be forced to travel diagonally and follow along the second cam segment15of the cam groove3until the locking pin9eventually reaches position the position shown inFIG.7C. That is, the first step13ensures, as soon as the locking pin9completely transitions into the second cam segment15, that any subsequent upward force, from the crane, will cause locking pin9to travel along the second cam segment15of the cam groove3to the position shown inFIG.7Cand not back toward the entrance EN of the cam groove3. FIG.7A through7Cillustrate the interaction between locking pin9and the cam groove3as the crane now begins to move the second upper assembly2relative to the first lower assembly1. After the second upper assembly2is lowered to its bottom most position and the weight of the second upper assembly2is partially or fully transferred to the wellhead to permit the transition of the locking pin9to occur, the crane operator then lifts up on the second upper assembly2to move the locking pin9to engage and lock the connection. As a result of such movement, the locking pin9now travels, as indicated, along a diagonal path into the locked position shown inFIG.7C. FIG.7Dshows the detail of cam groove3at the end of the second cam segment15and the beginning of the third cam segment17. As shown, a second step16, e.g., a radially inward step of between 1/16 to 1 inch or so and more preferably a step of about ½ of an inch, is located at the transition between the end of the second cam segment15and the beginning of the third cam segment17of the cam groove3. That is, the end of the second cam segment15, adjacent the beginning of the third cam segment17, is located radially further away from the central axis CA than the beginning of the third cam segment17so as to form a step therebetween. As the second upper assembly2is lifted by the crane, the locking pin9eventually passes or transitions over the second step15, located between the second and the third cam segments15,17of the cam groove3. Once the locking pin9is completely located within the beginning of the third cam segment17, the spring10forces the locking pin9radially inward a small distance, e.g., the thickness or the height of the second step16. As a result of this, the second step16now prevents the locking pin9from again following along the second cam segment15of the cam groove3. As such, the second step16functions to prevent the respective locking pin9from retracing its path downward along the second cam segment15of the cam groove3. Accordingly, when the crane again exerts a lowering force on the second assembly2, the locking pin9will thus be forced to travel diagonally and follow along the third cam segment17of the cam groove3until the locking pin9eventually reaches position the position shown inFIG.9C. That is, the second step16ensures, as soon as the locking pin9completely transitions into the third cam segment17, that any subsequent downward force, from the crane, will cause locking pin9to travel along the third cam segment17of the cam groove3to the position shown inFIG.9Cand not back toward the position shown inFIG.4C. When the locking pin9is located in the position shown inFIG.7C, the second upper and first lower assemblies1,2are locked together in a way that can withstand the axial forces generated by the high internal pressure created within the connection between the first lower and second upper assemblies1,2. As long as tension is exerted axially in the form of an upward lifting force from the crane or other hoisting equipment, the locking pin9cannot move up or down along the cam groove3. Turning now toFIG.8, this figure shows the fully locked position of the present invention. This figure shows the position of the pressurizable assembly PA with all four locking pins9engaged so as to create an axial link capable of withstanding maximum working pressures of more than 10 ksi, for example. This figure also illustrates that the locking pins9function as visual indicators signifying that the locking pins9are in there proper locked positions. That is, when the locking pins are fully depressed by the springs10radially inward in the locked position ofFIG.7Cfor example, the rear surface25of the locking pin9will be generally fully retracted into the locking pin housing and thus generally not visible to an operator thereby providing a visual feedback that the mechanism is fully engaged and locked. FIGS.9A through9Cillustrate the interaction between locking pin9and the cam groove3as the disconnection process of the first lower and upper assemblies1,2begins. When disconnection between the upper and lower assemblies1,2is desired, the crane operator again lowers second upper assembly2. As this occurs, the second step16causes the locking pins9to follow along the third cam segment17of the cam groove3, downward and toward the right, as shown inFIGS.9A-9C, toward the beginning of the fourth cam segment19. The interaction of the second step16of cam groove3and the constant radial inward force on the locking pin9cause the locking pin9to travel along the fourth cam segment17rather than travel back in the direction toward the beginning of the second cam segment15of the cam groove3.FIG.9Dshows the detail of cam groove3of at the end of the third cam segment17and the beginning of the fourth cam segment19. As shown, a third step18, e.g., a radially inward step of between 1/16 to 1 inch or so and more preferably a step of about ½ of an inch, is located at the transition between the end of the third cam segment17and the beginning of the fourth cam segment19of the cam groove3. That is, the end of the third cam segment17, adjacent the beginning of the fourth cam segment19, is located radially further away from the central axis CA than the beginning of the fourth cam segment17so as to form a step therebetween. As soon as the locking pin9is completely located within the beginning of the fourth cam segment19, the spring10forces the locking pin9radially inward a small distance, e.g., the thickness of the third step18. As a result of this, the third step18now prevents the locking pin9from again following along the third cam segment17of the cam groove3. As such, the third step18functions to prevent the respective locking pin9from retracing its path upward along the third cam segment17of the cam groove3. Accordingly, when the crane again exerts a lifting force on the second assembly2, the locking pin9will thus be forced to travel upward and follow along the fourth cam segment19of the cam groove3until the locking pin9eventually reaches position the position shown inFIG.10C, before exiting the cam groove3. That is, the third step18ensures, as soon as the locking pin9completely transitions into the fourth cam segment19, that any subsequent upward force, from the crane, will cause locking pin9to travel along the fourth cam segment19of the cam groove3to the position shown inFIG.10Cand not back toward the position shown inFIG.7C.FIGS.10A through10CIllustrate the interaction between the locking pin9and the cam groove3as the disconnection process is completed. Once the second upper assembly2is lowered until the second upper assembly2either partially or fully rests on the wellhead, the crane then operator exerts a force which again lifts the second upper assembly2, relative to the first lower assembly1, to facilitate complete disengagement of the second upper assembly2from the first lower assembly1. FIG.10Dillustrates the geometry of cam groove3such that the cam groove3will allow the second upper assembly2to be removed from the first lower assembly1. As the second upper assembly2is lifted, the locking pin9will move toward the end of the fourth cam segment and eventually transition or step over the fourth step20, e.g., a radially inward step of between 1/16 to 1 inch or so and more preferably a step of about ½ of an inch, from the end of the fourth cam segment19back to the cylindrical surface24which is located radially closer to the central axis A. As soon as the locking pin9transitions over the fourth step20, the fourth step20with, thereafter, prevent the locking pin9from traveling back along the fourth cam segment19toward the lower most position shown inFIG.9C. Because of fourth step20and the fact that locking pins9are radially forced inward, any subsequent lowering of second upper assembly2would cause locking pin9to be guided toward the entrance EN of the cam groove3, as shown inFIG.4A, and thereby prevent the locking pin9from travelling back through the exit EX of the cam groove3and toward the position shown inFIG.10A. Thus, through this series of (e.g. four) cam segments13,15,17,19, with a step14,16,18,20being formed between the end of one segment and the beginning of the next segment, the locking pins are forced to travel along the respective cam groove3along a single direction of travel. As a result, a first cycle of downward and upward motion of the second upper assembly2, relative to the first lower assembly1, will advance locking pins9into their locked positions (seeFIG.7C), and a subsequent second cycle of downward and upward motion of the second upper assembly2, relative to first lower assembly1, will advance locking pins9into their unlocked position in which the second upper assembly2can be removed and separated from the first lower assembly1. FIG.11shows the relative motion of a single locking pin9along and through a single cam groove3to further illustrate the principle of the coupling mechanism of the present invention. As the second upper assembly2is lowered, relative to the first lower assembly1, each one of the locking pins9will be guided into the entry EN and then travel from position A to position B in the direction of the arrow labelled ENTRY. Position B is the lowest point of the lock phase. When the second upper assembly2is then lifted, as noted above, due to the transition of the locking pin9over the first step13, the locking pin9cannot travel back along the first cam segment13toward the entry EN and is thus forced to travel in the only possible direction—that is in the direction of the arrow labelled LOCK until the respective locking pin9reaches position C which is the locked position. At this point, any further upward force on second upper assembly2will not cause any relative movement between locking pin9and the respective cam groove3, it will simply result in axial load being transferred to the first lower assembly1. Since, at position C, the depth of the UNLOCK groove is greater than the depth of the LOCK groove, any subsequent lowering of the second upper assembly2cannot result in locking pin9traveling back in the LOCK direction. When second upper assembly2is lowered, locking pin9must advance in the direction of the arrow marked UNLOCK until the locking pin9reaches position D which is the lowest point of the unlock phase. At position D, the locking pin9again experiences a step change in the depth of cam groove3which will not permit the locking pin9to travel back in the UNLOCK direction. Subsequent upward force on second upper assembly2will result in locking pin9traveling along the only possible direction which is in the direction of the arrow marked EXIT. Further upward motion of second upper assembly2will result in locking pin9travelling all the way out of cam groove3ultimately resulting in complete decoupling of the second upper assembly2from the first lower assembly1. Now turning toFIG.12, another possible geometry for the cam groove3is diagrammatically shown.FIG.12, shows the relative motion of a single locking pin9through a single cam groove3to again illustrate the coupling mechanism of the present invention. The movement of the locking pin9is substantially the same as described above while following the cam groove which has a different shape. As the second upper assembly2is lowered relative to the first lower assembly1, each of the locking pins9will be guided into the entry EN and travel from position A toward position B in the direction of the arrow labelled ENTRY. Position B is the lowest point of the lock phase. When second upper assembly2is then lifted, as noted above, due to the transition of the locking pin9over the first step13, the locking pin9cannot travel back along the first cam segment13toward the entry EN and is thus forced to travel in the only possible direction—that is in the direction of the arrow labelled LOCK—until the locking pin9reaches position C which is the locked position. At this point, any further upward force on the second upper assembly2will not cause any relative movement between the locking pin9and the cam groove3, it will simply result in the axial load being transferred to first lower assembly1. Since, at position C, the depth of the UNLOCK groove is greater than the depth of the LOCK groove, any subsequent lowering of the second upper assembly2cannot result in the locking pin9traveling back in the LOCK direction. When second upper assembly2is again lowered, the locking pin9must advance in the direction of the arrow marked UNLOCK until the locking pin9reaches position D which is the lowest point of the unlock phase. At position D, the locking pin9again experiences a step change in the depth of cam groove3which will not permit the locking pin9to travel back in the UNLOCK direction. Subsequent upward force on second upper assembly2will result in locking pin9traveling along the only possible direction which is in the direction of the arrow marked EXIT. Further upward motion of the second upper assembly2will result in the locking pin9travelling all the way out of the cam groove3ultimately resulting in complete decoupling of second upper assembly2from the first lower assembly1. Turning now toFIG.13, a second embodiment of the present invention will now be briefly described. This embodiment is very similar to the previously discussed embodiment with the features of the second upper assembly2and the first lower assembly1being reversed. This embodiment is meant to illustrate that the present invention will function in the same manner regardless of which features remain stationary on first lower assembly which is affixed to the wellhead and which features are attached to second upper assembly which is moved by the moving crane. It should be noted that the specific geometry of the cam groove3in the embodiment pictured inFIGS.1through13are not an exhaustive description of the possible geometries of the present invention. Other alterations would still be considered to be within the spirit and scope of this invention provided they act as a mechanism that allows for a cycle of lowering and raising the second upper fitting/assembly2, relative to the first lower fitting/assembly1, to lock the two fittings/assemblies to one another so as to withstand the internal pressure and axial load of the maximum allowable working pressure, and that a subsequent lowering and raising cycle would allow for complete separation of the two fittings/assemblies from one another. It should also be noted that as the second upper assembly2is lowered by the crane, it will experience some degree of angular displacement as the locking pins travel through cam groove3, however this is ancillary motion and is not induced so as to create the fluid seal. All that is required for the present invention to achieve a coupled and decoupled state is the downward force of gravity and the upward force of the lifting equipment. Finally, it should be noted that the pictured embodiments illustrate the present invention with four locking pin mechanisms carried by one fitting/assembly and four corresponding cam grooves carried by the other fitting/assembly, however other embodiments could be devised with more or less features so long as the device provides adequate mechanical strength when the fittings/assemblies are coupled to one another to safely withstand the maximum allowable working pressure. Generally each one of the first, the second, the third and the fourth cam segments are slightly inclined cam surfaces which are interconnected with, but separated one another by a respective step so as to form a continuous cam groove that defines a single direction of travel for the locking pin through the cam groove. This arrangement ensures that the first and second assemblies1,2are consistently and reliably connected to one another by a simple downward lowering and then an upward lifting movement of the second upper assembly2relative to the first lower assembly1. This arrangement also ensures that the first and second assemblies1,2are consistently and reliably disconnected to one another by a simple downward lowering and then an upward lifting movement of the second upper assembly2relative to the first lower assembly1. As shown, each one of the plurality of spaced apart cam grooves of the first assembly generally has a “W” shaped configuration from the entrance to the exit. While various embodiments of the present invention have been described in detail, it is apparent that various modifications and alterations of those embodiments will occur to and be readily apparent to those skilled in the art. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the appended claims. Further, the invention described herein is capable of other embodiments and of being practiced or of being carried out in various other related ways. In addition, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having,” and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items while only the terms “consisting of” and “consisting only of” are to be construed in a limitative sense. The foregoing description of the embodiments of the present disclosure has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the present disclosure to the precise form disclosed. Many modifications and variations are possible in light of this disclosure. It is intended that the scope of the present disclosure be limited not by this detailed description, but rather by the claims appended hereto. A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the scope of the disclosure. Although operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. | 29,166 |
11859461 | DETAILED DESCRIPTION Systems of the present disclosure generally relate to an insert of lower yielded material that is installed underneath a pin nose. This provides an active support structure to bridge any gap between the pin nose to an underlying/lower support structure. The pin nose may also be supported by its underlying support structure without the insert. The gap between the pin nose and the underlying support structure is calculated and machined exactly such as when the two tubulars are fully mated, the pin nose contacts the underlying support structure. The enhanced connection is created via a soft insert or with a controlled gap which improves the pin's sealing performance in high pressure applications by providing additional support via the underlying support structure. This is an active support design which bridges the pin nose to the underlying support structure. The pin nose enhancement of the present disclosure expands the use case of existing metal-to-metal thread connections for applications in high pressure/high temperature scenarios. Due to a reduced wall stiffness/thickness limitation, pins of the present disclosure may include sections with reduced thicknesses allowing for slim applications. In order to prevent local yielding of the pin nose, the insert is designed with underlying yield-strength metallic materials such as, for example: inconel, stainless steel, brass, aluminum, aluminum bronze, or combinations thereof. Upon external collapse pressure, any deflection of the pin nose is supported by the underlying support. This design converts the pin nose from a cantilever type to a cantilever that is supported. The stiffness of the nose pin (cantilever) and contact stress is also distributed throughout the metal-to-metal sealing location. With added collapse pressure, the metal-to-metal contact pressure increases, thereby providing for more positive seal assurance. The insert may also be made of thermoplastic (e.g., PEEK, PTFE, PPS) and/or thermoset (e.g., epoxy, silicone, phenolic). The insert may also be made of elastomers (e.g., NBR, HNBR, FKM). The insert may also include a linear wave spring with sufficient spring force to support the pin nose. In some examples, the gap may be filled with a filler material. In other examples, the insert may be of a lattice structure (e.g., wire mesh with fillers). In some examples, a controlled gap between the pin and its underlying support may be used with the insert. The gap may be made by a manufacturing technique such as electric discharge machining (EDM). The gap between the pin nose and the insert allows for tubulars to be connected with either a controlled interference or no interference at all. In other examples, a void capacity underneath the pin may be fluid filled (gas or liquid) and closed off during assembly. As the pin is deployed downhole, temperature increase causes an expansion of the charged fluid thereby energizing the seal. FIG.1illustrates a pin100for a metal-to-metal connection for an oilfield tubular, in accordance with examples of the present disclosure. The pin100may be disposed on a distal end of an oilfield tubular102such as a tool or piping for disposal into a subterranean formation for exploration and/or production operations (hydrocarbon recovery), for example. The pin100may include a pin nose104for insertion into a box during mating of the pin to the box. A gap106may be disposed between the pin nose104and an underlying support structure108of the pin100. The underlying support structure108may be positioned radially inward from the pin nose104. For example, an outer diameter of the underlying support structure108is less than the inner diameter of the pin nose104. The underlying support structure108and the pin nose104may be coaxially and/or concentrically aligned and may each be of a tubular shape, as shown, for example. The gap106may extend along a circumference of the underlying support structure108. The gap106between the pin nose and the underlying support structure108is calculated and machined exactly such as when two tubulars (e.g., a pin and a box) are fully mated, the pin nose104contacts the underlying support structure108. Upon external collapse pressure, any deflection of the pin nose104is supported by the underlying support structure108. The gap106may be created by a manufacturing technique such as electric discharge machining (EDM). The gap106between the pin nose104and an insert allows for body joints to be made up with either a controlled interference or no interference at all. A size or thickness of the gap106may range, for example, from about 0.005 to 0.500 inches. FIG.2Aillustrates a cross-section of the pin100, in accordance with examples of the present disclosure. The pin100may include threads200for mating with a box resulting in a metal-to-metal seal therebetween. The pin nose104is illustrated in a non-deflected position state and does not bend toward the underlying support structure108, thereby leaving the gap106in an unaltered state. The gap106may extend in a direction along a longitudinal axis L of the pin nose104. In some examples, the gap106may extend beneath the pin nose104along the entire length of the pin nose104. In other examples, the gap106may extend along L, beneath a portion of the pin nose104. In some examples, the gap106may extend beneath the pin nose104along L, from a non-threaded section of the pin100to a distal end of the pin100. In some examples, a range for a length (in a direction along L) of the gap106may range from about 0.100 to 2.00 inches. A controlled gap improves the pin's sealing performance in high pressure applications by providing additional support from the underlying support structure108. The gap106between the pin nose104and the underlying support108is calculated and machined exactly such that when the two tubulars are fully mated, the pin nose104contacts the underlying support structure108. FIG.2Billustrates a cross-section of the pin100mated to a box201, in accordance with examples of the present disclosure. The box201may be a portion of another oilfield tubular. As an external force202is applied to the pin nose104via the box201, the pin nose104may bend toward and/or contact the underlying support structure108to provide an improved fluid seal for the threaded connection between the pin100and the box201. The pin nose104is illustrated in a compressed state, resulting in the gap106being altered to support the pin nose104. The gap106allows gradual deflection/bending of the pin nose104in a controlled manner. FIG.3Aillustrates a cross-section of the pin100with an insert300, in accordance with examples of the present disclosure. The insert300may be disposed in the gap106to prevent or mitigate deflection of the pin nose104during exposure to an external pressure202. In some examples, the insert300may completely fill the gap106. The insert300is designed with lower yield-strength metallic materials such as, for example: inconel, stainless steel, brass, aluminum, aluminum bronze, or combinations thereof. Upon external collapse pressure, any deflection of the pin nose104is supported by the underlying support structure108. This design converts the pin nose104from a cantilever type to a cantilever that is supported. In some examples, the insert300may be made of thermoplastic (e.g., PEEK, PTFE, PPS) and thermoset (e.g., epoxy, silicone, phenolic). In other examples, the insert300may be made of elastomers (e.g., NBR, HNBR, FKM). The pin nose stiffness and contact stress is also distributed throughout the metal-to-metal sealing location. With added collapse pressure, the metal-to-metal contact pressure increases, thereby providing for more positive seal assurance. FIG.3Billustrates a cross-section of the pin100with a linear wave spring302used as an insert, in accordance with examples of the present disclosure. The linear wave spring302may be disposed in the gap106. The linear wave spring302includes sufficient spring force to support the pin nose104. In some examples, the linear wave spring302may completely or substantially fill the gap106. FIG.3Cillustrates a cross-section of the pin100with a filler material304, in accordance with examples of the present disclosure. The gap106may be filled with a filler material304such as for example an expandable alloy. As the alloy contacts downhole fluids, an expansion reaction occurs which energizes the metal-to-metal seal. The filler material304may support the pin nose104. In some examples, the filler304may completely or substantially fill the gap106. FIG.3Dillustrates a cross-section of the pin100with a lattice structure306, in accordance with examples of the present disclosure. The gap106may be filled with the lattice structure306(e.g., wire mesh with fillers). The lattice structure306may support the pin nose104. In some examples, the lattice structure306may completely or substantially fill the gap106. FIG.3Eillustrates a cross-section of the pin100with a void capacity308, in accordance with examples of the present disclosure. A void capacity308underneath the pin may be fluid filled (gas or liquid) and closed off/sealed during assembly via a plug310, for example. As the pin is deployed downhole, temperature increase causes an expansion of the charged fluid thereby energizing (e.g., actuating, expanding) the metal-to-metal seal. Accordingly, the systems of the present disclosure improve sealing for metal-to-metal connections for oilfield tubulars. The systems may include any of the various features disclosed herein, including one or more of the following statements. Statement 1. An oilfield tubular comprising a pin for a metal-to-metal seal, the pin comprising a pin nose and a support structure, wherein a gap extends between the pin nose and the support structure. Statement 2. The oilfield tubular of the statement 1, wherein the gap extends along a circumference of the support structure. Statement 3. The oilfield tubular of any of the preceding statements, wherein the gap is operable to close due to deflection of the pin nose toward the support structure. Statement 4. The oilfield tubular of any of the preceding statements, further comprising an insert disposed in the gap. Statement 5. The oilfield tubular of any of the preceding statements, further comprising a spring disposed in the gap. Statement 6. The oilfield tubular of any of the preceding statements, further comprising a filler material in the gap. Statement 7. The oilfield tubular of any of the preceding statements, further comprising a fluid sealed in the gap. Statement 8. The oilfield tubular of any of the preceding statements, further comprising an insert disposed in the gap, the insert comprising inconel, stainless steel, brass, aluminum, aluminum bronze, or combinations thereof. Statement 9. The oilfield tubular of any of the preceding statements, further comprising an insert disposed in the gap, the insert comprising thermoplastic and/or thermoset. Statement 10. The oilfield tubular of any of the preceding statements, further comprising an insert disposed in the gap, the insert comprising an elastomer. Statement 11. A pin for a metal-to-metal seal, the pin comprising a pin nose and a support structure, wherein a gap extends between the pin nose and the support structure. Statement 12. The pin of the statement 11, wherein the step of coating comprises coating the resin onto the proppant in a frac tub during a fracking operation. Statement 13. The pin of the statement 11 or the statement 12, wherein the step of coating comprises coating the resin onto the proppant that is positioned on a sand screw during a fracking operation. Statement 14. The pin of any of the statements 11-13, further comprising an insert disposed in the gap. Statement 15. The pin of any of the statements 11-14, further comprising a spring disposed in the gap. Statement 16. The pin of any of the statements 11-15, further comprising a filler material in the gap. Statement 17. The pin of any of the statements 11-16, further comprising a fluid sealed in the gap. Statement 18. The pin of any of the statements 11-17, further comprising an insert disposed in the gap, the insert comprising inconel, stainless steel, brass, aluminum, aluminum bronze, or combinations thereof. Statement 19. The pin of any of the statements 11-18, further comprising an insert disposed in the gap, the insert comprising thermoplastic and/or thermoset. Statement 20. The pin of any of the statements 11-19, further comprising an insert disposed in the gap, the insert comprising an elastomer. It should be understood that the compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the elements that it introduces. For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited as well as ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited. Therefore, the present embodiments are 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 embodiments may be modified and practiced in different but equivalent manners. Although individual embodiments are discussed, all combinations of each embodiment are contemplated and covered by the disclosure. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. 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. If there is any conflict in the usages of a word or term in this specification and one or more patent(s) or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted. | 15,376 |
11859462 | DETAILED DESCRIPTION If appearing herein, the term “comprising” and derivatives thereof are not intended to exclude the presence of any additional component, step or procedure, whether or not the same is disclosed herein. In order to avoid any doubt, all compositions claimed herein through use of the term “comprising” may include any additional additive, adjuvant, or compound, unless stated to the contrary. In contrast, the term, “consisting essentially of” if appearing herein, excludes from the scope of any succeeding recitation any other component, step or procedure, except those that are not essential to operability and the term “consisting of”, if used, excludes any component, step or procedure not specifically delineated or listed. The term “or”, unless stated otherwise, refers to the listed members individually as well as in any combination. The articles “a” and “an” are used herein to refer to one or to more than one (i.e. to at least one) of the grammatical objects of the article. By way of example, “a seal” means one seal or more than one seal. The phrases “in one aspect”, “according to one aspect” and the like generally mean the particular feature, structure, or characteristic following the phrase is included in at least one embodiment of the present disclosure, and may be included in more than one embodiment of the present disclosure. Importantly, such phrases do not necessarily refer to the same embodiment. If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic. As used herein, directional terms, such as “above”, “below”, “upper”, “lower”, etc., are used for convenience in referring to the accompanying drawings. In general, “above”, “upper”, “upward” and similar terms refer to a direction toward the earth's surface along a wellbore, and “below”, “lower”, “downward” and similar terms refer to a direction away from the earth's surface along the wellbore. However, when applied to equipment and methods for use in environments that are deviated or horizontal, such terms may refer to a left to right, right to left, or other relationship as appropriate. Any reference to the term “uphole” means a segment of the wellbore located along the wellbore between a recited location of the wellbore and the point at which the wellbore meets the surface of the earth. Although the term “uphole” can imply reference to locations closer to the surface than the recited point or location, those skilled in the art will appreciate that it can refer to locations further away from the earth's surface if the well bore includes U-shaped portions, which for example may return to a higher elevation. Any reference to the term “downhole” means a segment of the wellbore located along the wellbore further into or further along the wellbore than the recited point or location. Although the term “downhole” can imply reference to locations further below the surface than the recited point or location, those skilled in the art will appreciate that it can refer to locations closer to the surface if the well bore includes U-shaped or similar segments, where for example the wellbore may run closer to the surface after having traversed wellbore sections further below the ground. A “well” can include, without limitation, an oil, gas, or water production well, an injection well, or a geothermal well and which includes at least one wellbore. The term “wellbore” and variations thereof, as used herein, refers to a cased or uncased hole drilled into the earth's surface to explore or extract natural materials, including water, gas and oil. The wellbore can include vertical, inclined, and horizontal portions, and it can be straight, curved, or branched. The terms “casing” and variations thereof, as used herein, refers to large diameter pipe that is assembled by coupling casing sections in an end-to-end configuration which is positioned within a previously-drilled wellbore and which remains within the wellbore after completion of the wellbore to seal walls of the subterranean formation within the wellbore. Furthermore, the term casing includes wellbore casing and casing sections as well as wellbore liner and liner sections. The casing may be made of any suitable material, such as a metal, an alloy, a polymer and a composite. The term “tubing string” may include, but is not limited to, jointed tubing, coiled tubing, drill pipe, wireline, slick line, or other suitable conveyances and may be made of any suitable material such as a metal, an alloy, a polymer or a composite. The term “fluid” shall comprehend both liquids and gases and any combination thereof. The attached Figures depict a bottom hole assembly in accordance with one illustrative embodiment of the subject matter disclosed herein positioned in a wellbore. In general, the illustrative bottom hole assembly depicted herein comprises a by-pass valve assembly, a resettable sealing assembly and a shifting tool assembly. In use, the bottom hole assembly, particularly the by-pass valve assembly, will be coupled (directly or indirectly) to tubing string such that the tubing string is in fluid communication with the bottom hole assembly. In some applications, various devices (not shown) may be positioned between the tubing string and the bottom hole assembly. For example, a check valve assembly (dual flapper valve), a release tool, a burst disk or other well-known downhole components may be positioned above the illustrative by-pass valve assembly. The use and structure of such additional devices are well known to those skilled in the art. Accordingly, further details of such additional devices are not provided so as not to obscure the present disclosure. Referring generally toFIG.1, a well system1is depicted deployed in a wellbore2. In the illustrated embodiment, the well system1comprises a completion string6deployed within the wellbore2via, for example, tubing string. In many applications, the completion string6is deployed within a cased wellbore having a casing3, however the completion string6can also be deployed in an uncased wellbore (i.e. an open hole application). As illustrated, the completion string6comprises at least one well tool7, with one or more of the well tools7being shiftable between two or more configurations. The well tool7may have a variety of shapes and sizes as well as profiles for location purposes. Depending on the application, the well tool7may comprise, for example, one or more: (a) valves including ball valves, flapper valves, disk valves, flow control valves, circulating or reversing valves, and other valves that are shifted during a given downhole procedure; (b) plugs or (c) sliding ports or sleeves. In the embodiment shown inFIG.1, the well tools7are shown as collars or subs for attachment of adjacent lengths of tubing string. It is, however, contemplated that a similar well tool configuration could be used in other applications, that is, as collars or subs for attachment of adjacent lengths of casing for lining wellbore2, whether cemented in place or otherwise positioned within wellbore2. The well system1further comprises a bottom hole assembly10according to the present disclosure and a deployment mechanism8. Depending on the specific application, the deployment mechanism8may have a variety of forms. For example, the deployment mechanism8may comprise tubing string. Additionally or alternatively, a tractor or stroker9can be used to move bottom hole assembly10. In the illustrated embodiment, the bottom hole assembly10can be moved along the interior of wellbore2for selective engagement with one or more of the well tools7. The deployment mechanism8is only shown for illustrative purposes, and thus is not included in each Figure depicting an embodiment of the bottom hole assembly10. Referring toFIG.1a, the bottom hole assembly10is depicted according to one embodiment of the present disclosure. As described above, the bottom hole assembly10is intended to be incorporated into a deployment mechanism8(not shown), which will be referred to throughout the remainder of the present disclosure as tubing string, with an upper end12aof the bottom hole assembly10being adapted for connection to an upper tubing string and a lower end12bof the bottom hole assembly being adapted for connection to a lower tubing string or in some aspects (as shown) is not adapted for connection to a lower tubing string. The bottom hole assembly10will therefore have a fluid flow passage therethrough. The ends of bottom hole assembly10can be formed for connection in various ways. For example, they can be threaded or have other forms or structures to permit alternate forms of connection. Fluid flow occurs lengthwise through the upper tubing string, and thus through bottom hole assembly10, during wellbore operations. As will be described in more detail below, the bottom hole assembly10is operable in at least four configurations and generally includes i) a by-pass valve assembly20having an uphole end20aand a downhole end20band a first flow passage24extending therebetween and at least one port16for fluid communication from the first flow passage24to an annular area outside the bottom hole assembly when the by-pass valve assembly20is in an open position, ii) a resettable sealing assembly39having an uphole end39aand a downhole end39band a second flow passage34extending therebetween in fluid communication with the first flow passage24when the by-pass valve assembly is a closed position, and iii) a shifting tool assembly50having an uphole end50aand a downhole end50band a third flow passage54extending therebetween in fluid communication with the second flow passage34and a restriction nozzle57positioned at the downhole end. It will be appreciated that the bottom hole assembly10of the present disclosure generally relates to an apparatus and method for performing multiple operations within a length of tubing, in some aspects in a single trip, the length of tubing having ports, slots, apertures or other pathways through which fluid can be delivered laterally from the tubing string to the wellbore. Accordingly, the term “housing” is generally used to refer to a length of tubing through which fluid flow can occur lengthwise and having a fluid passage for lateral fluid communication between an inlet and an outlet of the housing. It will also be appreciated that the by-pass valve assembly20, resettable sealing assembly39and shifting tool assembly50can be connected within the bottom hole assembly10in various ways, such as through adaptors or connectors or other means known in the art. According to one embodiment, the by-pass valve assembly20can be positioned at the top of the bottom hole assembly10and can be fluid pressure controlled to direct fluid flow to: (i) the exterior of the bottom hole assembly10through port16in one valve orientation; or (ii) the shifting tool assembly50through the resettable sealing assembly39in another valve orientation. The by-pass valve assembly20is moveable between orientations (i) and (ii) by reaction to a pressure differential. Since the by-pass valve assembly20is capable of communicating fluid to the exterior of the bottom hole assembly10in one orientation when in an open position and to the shifting tool assembly50in another orientation when in a closed position, it is operable in connection with at least two steps during a hydraulic fracture operation: wellbore fracking and downhole shifting of a well tool. Referring toFIGS.2,3,3a,3band4a, in one embodiment, the by-pass valve assembly20includes a valve21positioned therein with a housing22configured to slide axially relative to an outer sleeve23in response to a pressure differential across the valve21. Thus, the valve21includes a longitudinally sliding housing22with a longitudinal central axial bore24for the passage of fluids conveyed by the upper tubing string. The outer sleeve23has one or more ports16in its sidewall. The housing22has one or more corresponding openings22a. When the one or more ports16and the one or more openings22aare aligned (as illustrated inFIGS.2and4a), valve21is in an “open” position and fluid pumped through central axial bore24may exit the bottom hole assembly10through opening22aand port16in a radial direction; and, fluid flow towards and through the resettable sealing assembly39and shifting tool assembly50is blocked. When port16and opening22aare not aligned (as illustrated inFIGS.3,3aand3b), valve21is in a “closed” position and fluid pumped down central axial bore24is directed through openings22aand into annular channel28which directs fluid flow past port16towards and through the resettable sealing assembly39and the shifting tool assembly50located downhole from the by-pass valve assembly20. In this embodiment, each of the ports16and openings22aare shown as oval, however each can be any other suitable shape, such as a slot or circular, polygonal or kidney-shaped. According to one embodiment, the valving between the flow paths is provided by a piston25slidably positioned in central axial bore24. The piston25may have two opposed piston faces: an upper piston face25aopen to a first pressure above the piston25; and, a lower piston face25bopen to a second pressure below the piston25. As such, the piston25may move based on different effective forces acting on the piston faces. For example, when the first pressure above the piston25is equal to or greater than the second pressure below piston25, the effective force acting on the upper piston face25awill be equal to or greater than the effective force acting on the lower piston face25band will drive the piston25down resulting in housing22moving down and the valve21being in the open position. The piston25will not move up to drive housing22up and close the valve21until the second pressure below the piston25is sufficient to overcome the first pressure-induced force acting on the upper piston face25a. As will be appreciated, the first pressure and the second pressure can be adjusted through the tubing string and bottom hole assembly10by pressure adjustment means including, but not limited to, pumping fluids from the surface, pressure relief and flow restriction devices. Referring toFIG.1a, the bottom hole assembly10further includes the resettable sealing assembly39positioned below or downhole of the by-pass valve assembly20and above or uphole of the shifting tool assembly50. The resettable sealing assembly39serves to maintain the position of the bottom hole assembly10downhole and ensures the portion of the wellbore above the resettable sealing assembly39is hydraulically isolated from the portion of the wellbore below the resettable sealing assembly39. Various tools for downhole use as the resettable sealing assembly39can include, but are not limited to, bridge plugs, friction cups, inflatable packers and mechanically actuated compressible packers. According to one embodiment, the resettable sealing assembly39comprises a packer assembly30and a drag-slip assembly40. Referring toFIG.2, the packer assembly30can include a housing31with a longitudinal central axial bore34extending between upper and lower and ends of the housing and operable for the passage of fluids conveyed by the upper tubing string and through the by-pass valve assembly20. The drag-slip assembly40is mounted over the packer assembly30and is configured to slide axially relative to the packer assembly30. The packer assembly30and the drag-slip assembly40are configurable between an unset position (FIGS.2and5) and a set position (FIG.4). The packer assembly30further includes one or more packing elements32annularly formed and encircling housing31. The packing element32has an outer facing surface32aand an inner facing surface32boperable to create a seal in the wellbore by compression during the set position. For example, in the unset position, (FIG.2) the packer assembly30is in a neutral, uncompressed position with the packing element32retracted, for example, to an outer diameter less than the inner diameter of the completion string wall or casing wall in which the bottom hole assembly10is positioned. However, in the set position (FIG.4) packer assembly30is in a compressed condition with packing element32extruded radially outwardly. For example, during the set position, packing element32has an outer diameter pressed against the inner wall of the completion string or casing and therefore equal to the inner diameter of the completion wall or casing wall. Thus, outer facing surface32ais engaged with the inner wall of the completion string or casing and inner facing surface32bis engaged with the outer surface of housing31. Packer assembly30may be returned to the unset position (FIG.5) by releasing the compressive force on the packer assembly30, after which the packing element32will return to the retracted position. The packing element32can be formed of an elastomeric material, and upon application of compressive forces against its sides, can be squeezed radially outwardly. “Elastomer” as used herein is a generic term for substances emulating natural rubber in that they stretch under tension, have a high tensile strength, retract rapidly, and substantially recover their original dimensions (or even smaller in some embodiments). The term includes natural and man-made elastomers, and the elastomer may be a thermoplastic elastomer or a non-thermoplastic elastomer. The term includes blends (physical mixtures) of elastomers, as well as copolymers, terpolymers, and multi-polymers. Examples include ethylene-propylene-diene polymer, various nitrile rubbers which are copolymers of butadiene and acrylonitrile such as Buna-N, polyvinylchloride-nitrile butadiene blends, chlorinated polyethylene, chlorinated sulfonate polyethylene, aliphatic polyesters with chlorinated side chains such as epichlorohydrin homopolymer, epichlorohydrin copolymer, and epichlorohydrin terpolymer, polyacrylate rubbers such as ethylene-acrylate copolymer, ethylene-acrylate terpolymers, elastomers of ethylene and propylene, sometimes with a third monomer, such as ethylene-propylene copolymer, ethylene vinyl acetate copolymers, fluorocarbon polymers, copolymers of poly(vinylidene fluoride) and hexafluoropropylene, terpolymers of poly(vinylidene fluoride), hexafluoropropylene, and tetrafluoroethylene, terpolymers of poly(vinylidene fluoride), polyvinyl methyl ether and tetrafluoroethylene, terpolymers of poly(vinylidene fluoride), hexafluoropropylene, and tetrafluoroethylene, terpolymers of poly(vinylidene fluoride), tetrafluoroethylene, and propylene, perfluoroelastomers such as tetrafluoroethylene perfluoroelastomers, highly fluorinated elastomers, butadiene rubber, polychloroprene rubber, polyisoprene rubber, polynorbornenes, polysulfide rubbers, polyurethanes, silicone rubbers, vinyl silicone rubbers, fluoromethyl silicone rubber, fluorovinyl silicone rubbers, phenylmethyl silicone rubbers, styrene-butadiene rubbers, copolymers of isobutylene and isoprene known as butyl rubbers, brominated copolymers of isobutylene and isoprene and chlorinated copolymers of isobutylene and isoprene. The packer assembly30further includes compression collars33and35, these collars also being annularly formed to encircle housing31. Compression collar35can include an upper shoulder36and a guide surface37. During the set position, when the packer assembly30and packing element32are compressed and squeezed out between the compression collar33and the upper shoulder36of the compression collar35(FIG.4), the outer facing surface32aof the packing element32is driven into contact with the inner wall of the completion string or casing in which the bottom hole assembly10is positioned. At the same time, the inner facing face32bof the packing element32becomes pressed against the housing31. As a result, the packing element32forms a seal in the annular area between the housing31and the inner wall of the completion string to prevent fluids from passing through the annular area. The compression collars33and35and the upper shoulder36can be formed of rigid materials, such as a metal or an alloy, to transfer compressive forces to the packing element32. The compression collars33and35and the upper shoulder36may also have a radial thickness selected to resist lateral extrusion of the packing element32, and instead direct the packing element32radially outward as it's compressed. The force to achieve compression of the packing element32can be a result of pushing one compression collar toward the other while the other is held stationary. The other compression collar may also have a pushing force applied thereto, but as the bottom hole assembly10is intended for downhole use, routinely force is applied from the surface by manipulation of the upper tubing string, into which the bottom hole assembly10is connected, while a part of the tool is held steady. For example, if the bottom hole assembly10is installed with end12aconnected to the upper tubing string with the upper tubing string extending uphole toward the surface, force can be applied by lowering (pushing) or pulling on the upper tubing string. In this embodiment, the packer assembly30can be compressed by lowering or pushing down on the upper tubing string attached at end12awhile the drag-slip assembly40is held stationary. The drag-slip assembly40is thus operable to create a fixed stop or anchor against which the packer assembly30and packing element32can be compressed and expanded out radially. The packer assembly30and drag-slip assembly40may therefore be operable to set and unset the packer assembly30using tubing reciprocation: put weight on the upper tubing string when in tension (to set) and pull up on the tubing string (to unset). To be operable as a fixed stop or anchor, the drag-slip assembly40can include a locking mechanism for locking its position relative to the inner wall of the completion string or casing in which the bottom hole assembly10is positioned. For example, the drag-slip assembly can include a body41and a drag mechanism carried by the body41which is formed to engage the inner wall of the completion string or casing. The drag mechanism may include for example, one or more drag blocks43that are biased radially outwardly from body41, for example, by springs44. The drag block43can include an outer engaging face43aformed to frictionally engage, and provide resistance to movement along the surface of the completion string's or casing's inner wall. While the drag block43can be forced to move across the inner wall of the completion string, the drag block43frictionally engages against the surface of the completion string's or casing's inner wall such that a resistance force is generated by movement of the drag block43. This resistance is transferred to body41such that the movement of the drag-slip assembly40relative to the inner wall of the completion string or casing is also resisted. Thus, if the bottom hole assembly10is moved through the completion string or casing defined by such an inner wall, the drag-slip assembly40can only be moved along the inner wall by applying a force to the drag-slip assembly40, for example by putting weight on (i.e. pushing) or pulling up on the tubing string carrying the bottom hole assembly10. As noted above, the drag-slip assembly40can be locked into a position relative to the packer assembly30while the tubing string is lowered or pushed down through these members until packer assembly30, and in particular packing element32, is compressed between the compression collar33and the shoulder36of compression collar35. While the drag block43may be selected to lock drag-slip assembly40in a position for this purpose, a stronger locking mechanism may be further required to lock the position of the drag-slip assembly40. Thus, in this embodiment, the drag-slip assembly40further includes one or more anchor slips45carried on body41. The anchor slip45is normally retracted but can be driven radially out into engagement with the inner wall of the completion string or casing in which the bottom hole assembly10is positioned to lock the drag-slip assembly40in a selected position when appropriate to do so. The anchor slip45includes a keeper46that holds the anchor slip45on body41. The anchor slip45can also include teeth45aon the outer face of the anchor slip45, the teeth45abeing selected to bite into the material of the inner wall of the completion string or casing. The teeth45amay be selected with consideration as to the hardness and material of the inner wall of the completion string or casing, for example, a metal or an alloy surface, or an exposed wellbore wall. The drag-slip assembly40further includes a mechanism for driving the one or more anchor slips45radially out from the retracted positon. The anchor slip45may be driven out by employing various mechanisms known to those skilled in the art. In this embodiment, the driving mechanism operates in response to compressive force applied to the bottom hole assembly10. For example, in the illustrated embodiment, an expansion force is driven by the guide surface37having an angled face, illustrated as frustoconically-shaped, that functions in cooperation with a compressive force applied along axis x of the bottom hole assembly10and packer assembly30. In this aspect, the compressive force is applied by pushing down on the upper tubing string which transfers the compressive force through by-pass valve assembly20and the packer assembly30and to the guide surface37, while the drag-slip assembly40is maintained in a position fixed against axial movement. Since the drag-slip assembly40cannot move, any compressive force applied to the bottom hole assembly10acts to move the anchor slip45out due to the shape of the face of the guide surface37. Thus, in this embodiment, it is the guide surface37that bears against the anchor slip45. The anchor slip45is in a position to be lifted by the guide surface37when the end of the guide surface37is urged beneath the anchor slip45. For example, when a compressive force is exerted by the upper tubing string, guide surface37passes beneath the anchor slip45and acts to move the anchor slip45radially outwardly into contact with the inner wall of the completion string or casing in which the bottom hole assembly10is positioned. As will be appreciated, the outer diameter of the guide surface37and the thickness of the anchor slip45, where they overlap, must be selected with consideration as to the distance between the bottom hole assembly10and inner wall of the completion string or casing. To more efficiently and stably translate compressive axial motion into radially directed force to drive the anchor slip45radially outward, the backside surface of the anchor slip45may also be shaped to have an angled face similar to that of guide surface37. Accordingly, in this embodiment, the one or more drag blocks43provide an initial resistance to a compressive force that permits the one or more anchor slips45to become initially engaged with the guide surfaces37and the anchor slips45provide the locking effect necessary for setting the packer assembly30when additional compressive force is applied to the bottom hole assembly10. In particular, the drag block43, through engagement with the inner wall of the completion string or casing in which the bottom hole assembly is positioned, provide an initial locking effect to hold the drag-slip assembly40stationary such that further applied compressive urges the anchor slip45over the guide surface37and radially outward to bite into the inner wall of the completion string or casing and hold the drag-slip assembly40more firmly in a locked position. Further compressive force can then be applied to compress and expand the packer assembly30and packing element32. Referring toFIG.2, the bottom hole assembly10further includes a shifting tool assembly50. The shifting tool assembly50can be positioned below or downhole of the resettable sealing assembly39, in this embodiment the packer assembly30and the drag-slip assembly40, and is adapted to manipulate a well tool, for example a ported tubular, and, for example, shift it from a first position (for e.g. a closed position) to a second positon (for e.g. an open position) or vice versa. Various examples of shifting tool assemblies useful in the present disclosure include, but are not limited to, the Otis® B Positioning Shifting Tool and Rapidshift® Hydraulic Shifting Tool (available from Haliburton), the B Shifting Tool (available from Brace Tool), the F/A Double Ended Selective Shifting Tool (available from National Oilwell Varco) and the SureShift™ Shifting Tool (available from Gryphon Oilfield Solutions). The shifting tool assembly50benefits from being pressure-activated. As discussed in more detail below, the shifting tool assembly50includes one or more shift keys56operable to extend radially out and engage the well tool in response to differential pressures within the bottom hole assembly10. For example, when there is no fluid flow in the shifting tool assembly50, springs53aand53bhold the shift key56in a retracted position. When fluid flow passes through shifting tool assembly50, the restriction nozzle57of the shifting tool assembly50is operable to create a differential pressure at the lower end50bof the shifting tool assembly. This differential pressure can provide an upward force which can be used to overcome the force exerted by the springs53aand53bthereby expanding the shift key56radially outward to engage or grip the well tool. Referring toFIGS.2and3, the shifting tool assembly50can include a housing52having one or more openings55(which can be circular, oval, a slot, polygonal or kidney-shaped) and a longitudinal central axial bore54extending between first and second ends51aand51b, respectively, and operable for the passage of a fluid conveyed by the upper tubing string and through the by-pass valve assembly20and resettable sealing assembly30. The shifting tool assembly50also includes the one or more shift keys56radially extendable from the shifting tool assembly so as to be selectably engageable with the surface of the well tool (not shown) that surrounds housing51. The shifting tool assembly50also includes the upper spring53aand a lower spring53bpositioned on opposite ends of the shift key56. Springs53aand53bare biased to hold the shift key56in a retracted position. When fluid is pumped down from the surface through the upper tubing string and through the bottom hole assembly10, a differential pressure can be created due to the presence of restriction nozzle57. Increasing the flow rate can force fluid flow through the one or more openings55causing pressure to build on a bottom face of shift key56. When this pressure exceeds the force exerted by the springs53aand53bto hold the shift key56in a retracted position, the shift key56will compress springs53aand53band expand out in a radial direction and engage the surface of the well tool. The upper tubing string can then be pushed down or pulled up to manipulate the well tool to shift the well tool from a first position (for e.g. closed) to a second position (for e.g. open) or vice versa as required. In use, the bottom hole assembly10should be properly located within the completion string or casing at the desired zone to shift and fracture. In some embodiments, locating the bottom hole assembly10may be accomplished using one or more mechanical collar locators (not shown). The use of such collars, and other similar means, for positioning the bottom hole assembly10at the desired location within the completion string or casing are well known to those skilled in the art, and thus they will not be described in any further detail. As noted above, the bottom hole assembly10is operable in at least four configurations. The bottom hole assembly10may be moved between the configurations hydraulically or application of tension or compression to the bottom hole assembly10via the tubing string and an auto-J mechanism. Auto-J mechanisms are well known to those skilled in the art and generally work by advancing a pin along various positions of a continuous j-slot track with the positions corresponding to a configuration of the bottom hole assembly. According to one embodiment the bottom hole assembly10may be run into a wellbore in a first configuration. In the first configuration, the by-pass valve assembly20is in a down position and valve21is an open position resulting in the one or more ports16and the one or more openings22abeing aligned. The packer assembly30is in a relaxed unset position and the one or more packing elements32are in a retracted position. The one or more anchor slips45and the one or more shift keys56are also in a retracted position. FIGS.2and7illustrate the bottom hole assembly10in the first (or run in) configuration. According to some embodiments, there is no fluid flow from the surface down through the upper tubing string and therefore no fluid flow through the bottom hole assembly10. According to other embodiments, the first configuration can also be used to circulate a fluid, such as a circulating fluid, down through the bottom hole assembly10, out the aligned port(s)16and opening(s)22aand up the annular area between the bottom hole assembly10and completion string or casing to the surface or vice versa. The circulating fluid can include, but is not limited to an aqueous liquid, such as water, solutions containing water, salt solutions, or water containing an alcohol or other organic solvent. “Water” as used herein includes, but is not limited to, freshwater, pond water, sea water, salt water or brine source, brackish water and recycled or re-use water, for example, water recycled from previous or concurrent oil- and gas-field operations. The pin in the j-slot track is in a position such that anchor slips45will not move along the packer assembly30and engage the guide surface37and therefore the packing element(s)32is in a retracted position. The bottom hole assembly10remains in the first configuration while it is being positioned at a particular location, such as adjacent to a well tool, within the completion string or casing by pulling up or pushing down on the tubing string. FIGS.3and8illustrate the bottom hole assembly10in the second (or shifting) configuration, after the bottom hole assembly10has been positioned within the completion string at a particular location. To initiate activation of the shifting tool assembly, the upper tubing is pulled up to force the housing22of valve21to slide up and port(s)16and opening(s)22ato become misaligned (i.e. valve21is in a closed position). A first fluid can then be pumped down from the surface through the tubing string and through the by-pass valve assembly20, packer assembly30and shifting tool assembly50. The first fluid can include, but is not limited to, an aqueous liquid. As the flow of the first fluid is increased, the differential pressure created by the first fluid flowing through the restriction nozzle57forces the first fluid to flow through the one or more openings55which causes pressure to build on the lower face of shift key(s)56, such pressure subsequently becoming large enough to overcome the force applied by springs53aand53band allowing the shift key(s)56to expand outward and engage the surface of the well tool, such as a ported tubular. The differential pressure created by the first fluid flowing through the restriction nozzle57can also act on the piston25of the by-pass valve assembly20to maintain the housing22in the up position and the valve21in a closed positon, and thus maintaining flow of the first fluid through the bottom hole assembly10. The pin in the j-slot track is in a position such that the anchor slip(s)45will not move along the packer assembly30and engage the guide surface(s)37and therefore the packing element(s)32will be in a retracted position. The bottom hole assembly10can thus be pulled up or pushed down while the shift key(s)56are expanded to shift a port of the ported tubular. Once shifting is completed, the flow of the first fluid can be reduced or stopped to reduce the differential pressure created by flow through the restriction nozzle57and thus collapsing the shift key(s)56. Thus, in summary, in the second configuration the by-pass valve assembly20is in an up position and valve21is in a closed position. The packer assembly30is in the unset position and the packing element(s)31and the anchor slip(s)45are in a retracted position. The shift key(s)56is expanded out from the bottom hole assembly10in a radial direction. While in the second configuration, the bottom hole assembly10, acting through the pulling up or pushing down on the tubing string, may be moved up or down in order to manipulate a well tool, such as shifting a port of a ported tubular along the completion string or casing from a first position (for e.g. closed position) to a second position (for e.g. open position). FIGS.4and9illustrate the bottom hole assembly10in the third (or treatment) configuration. In the third configuration, the by-pass valve assembly20(and housing22) has moved down and the valve21is again in an open position since the differential pressure created by fluid flow through the restriction nozzle57is no longer acting on the piston25to maintain the by-pass valve assembly20in the up position. The auto-J mechanism is cycled (by manipulating the tubing string) until the pin in the j-slot track is in a position such that the drag-slip assembly40and the anchor slip(s)45can move along the packer assembly30. The upper tubing string is then pushed down to drive the drag-slip assembly40into the packer assembly30causing the packer assembly30to compress and the packing element(s)32to expand radially outward to seal off the annular area between the outer surface of the bottom hole assembly10and inner wall of the ported tubular. The packing element(s)32also will compress against the outer surface of the housing31of the packer assembly30. While in the third configuration a portion of the wellbore above the packing element(s)32may be treated through the shifted port (or ports) in the completion string or casing by pumping a second fluid down from the surface through the tubing string. The treatment of the wellbore can be one or more of various treatments as would be appreciated by one of ordinary skill in the art. For example, the treatment may be, but is not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, or cementing. Accordingly the second fluid (or treatment fluid) can include, but is not limited to, any fluid that may be used in a subterranean application in conjunction with a desired function and/or for a desired purpose, such as a fracking fluid, an acidizing fluid, steam, gel, foam or water. Thus, in summary, in the third configuration the by-pass valve assembly20is in the down position and valve21is in the open position. The packer assembly30is in a set position with packing element(s)32compressed radially out against the inner wall of the completion string or casing. The anchor slip(s)45is also expanded to engage the inner wall of the completion string or casing to prevent undesired movement of the bottom hole assembly10during treatment. Further, the shift key(s)56has moved to a retracted position in the third configuration. FIGS.5and10illustrate the bottom hole assembly10in the fourth (or pull out) configuration. Tension can applied to the bottom hole assembly10by pulling the tubing string up which breaks the seal between the packing element(s)32, anchor slip(s)45and the completion string or casing to cause the pressure to equalize within the bottom hole assembly10subsequently causing the packing elements32and anchor slip(s)45to retract. The bottom hole assembly10may then be located at another well tool, such as a ported tubular, and may be moved through the second, third, and fourth configurations to open the ported tubular, set the packer assembly, treat the wellbore, and unset the packer assembly and release the bottom hole assembly from the ported tubular as discussed above. In summary, in the fourth configuration the bypass valve assembly20is in the up position and valve21is in the closed position. The packer assembly30is in the unset position and the packing element(s)32, anchor slip(s)45and the shift key(s)56are all in the retracted position. The bottom hole assembly10may then be moved from the first location to a second location within the wellbore to repeat the above progression for multiple treatments, if desired. FIG.6illustrates a flow chart depicting a method100for treating a wellbore according to the present disclosure. A bottom hole assembly10according to the present disclosure is positioned adjacent at least one of a plurality of ported tubulars along a completion string or casing located within a wellbore, the ported tubulars having at least one closed port and which is configured to permit selective treatment of the wellbore at step110. After positioning the bottom hole assembly10adjacent a ported tubular having at least one closed port at step110, a first fluid is pumped down from the surface through a tubing string attached to the top of the bottom hole assembly to activate the shifting tool assembly and expand the one or more shift keys56and engage the ported tubular having at least one closed port at step120. The first fluid can include, but is not limited to, an aqueous liquid. The bottom hole assembly10is then moved upwards or downwards to shift the at least one closed port of the engaged ported tubular from a closed positon to an open position at step130. Flow of the first fluid is stopped to deactivate the shifting tool assembly and retract the expanded shift key(s) at step140. The bottom hole assembly10is then pushed down via the tubing string to set the packer assembly30and drag-slip assembly40and expand the one or more packing element(s) and one or more anchor slip(s) at step150. A second fluid is pumped down from the surface through the tubing string and bottom hole assembly and the wellbore is treated through the opened port of the ported tubular at step160. The second fluid can include, but is not limited to, any fluid that may be used in a subterranean application in conjunction with a desired function and/or for a desired purpose, such as a fracking fluid, an acidizing fluid, steam, gel, foam or water. Flow of the second fluid is stopped and the bottom hole assembly is then pulled up via the tubing string to unset the packer assembly30and drag-slip assembly40and retract the packing element(s)32and anchor slip(s)45at step170. The bottom hole assembly10is positioned at another ported tubular having one or more closed ports along the completion string or the casing at step180. The method steps120-180can be repeated a plurality of times to open the one or more closed port(s) and treat the wellbore and position the bottom hole assembly at another ported tubular having one or more closed ports along the completion string or casing. Accordingly, it is possible with the use of the bottom hole assembly of the present disclosure to shift and treat a well in a single trip by conducting the steps discussed above. The reduction in the number of trips needed to perform these procedures through utilization of the bottom hole assembly of the present disclosure will result in substantial savings of time and expense associated with evaluating exploration wells. While the foregoing is directed to embodiment of the present disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. | 43,959 |
11859463 | DETAILED DESCRIPTION Disclosed herein are systems for isolating a setting chamber for a hydraulically actuated tool (e.g., hydraulic set packer) after setting the hydraulically actuating tool in the wellbore. Isolating the setting chamber may allow the system to operate under higher pressure while additionally reducing wall thickness and/or other parameters for components in the setting chamber to reduce manufacturing costs for the hydraulically actuated tool. FIG.1illustrates a wellbore completion system100having a hydraulically actuated tool102(e.g., a hydraulic set packer system200) disposed in a wellbore104, in accordance with some embodiments of the present disclosure. As illustrated, the hydraulically actuated tool102may be run-in-hole via a conveyance106(e.g., coiled tubing, segmented tubing, etc.) Once the hydraulically actuated tool102is positioned at a desired location in the wellbore104, fluid may be pumped through the conveyance106toward the hydraulically actuated tool102. As set forth in detail below, the fluid may have sufficient pressure to set the hydraulically actuated tool102. Moreover, continued pressure in the hydraulically actuated tool102, after the hydraulically actuated tool102is set, may further actuate a pressure isolation assembly configured to seal a portion of the hydraulically actuated tool102from the fluid pumped through the conveyance106. FIGS.2A-2Cillustrate cross-sectional views of a hydraulic set packer system200having a pressure isolation assembly202, in accordance with some embodiments of the present disclosure. In particular,FIG.2Aillustrates an embodiment of the hydraulic set packer system200in a pre-set state. That is, at least one radially actuatable component206of the hydraulic set packer system200is in a collapsed position such that the hydraulic set packer system200may be run-in-hole. As illustrated, the hydraulic set packer system200includes an outer sleeve210having a substantially hollow cylindrical shape with a radially outer sleeve surface212and a radially inner sleeve surface214. The outer sleeve210is positioned about a portion of a mandrel216. That is, the mandrel216extends through the outer sleeve210. The mandrel216also has a hollow cylindrical shape with a radially inner mandrel surface218and a radially outer mandrel surface220. A central bore222defined by the radially inner mandrel surface218is configured to convey fluid from the surface through the hydraulic set packer system200. Further, the mandrel216includes a setting port224extending through a radial wall226of the mandrel216(e.g., extending between the radially inner mandrel surface218and the radially outer mandrel surface220). The setting port224is configured to direct fluid from the central bore222to a setting chamber228. That is, the setting port224may provide fluid communication between the central bore222and the setting chamber228. The setting chamber228is formed between the outer sleeve210and the mandrel216. Specifically, the setting chamber228is formed between the radially inner sleeve surface214of the outer sleeve210and the radially outer mandrel surface220of the mandrel216. In the pre-set state of the hydraulic set packer system200, axial ends (e.g., a first axial end250and a second axial end252) of the setting chamber228may be sealed from the wellbore104via a piston230and a pressure isolation assembly202. In the illustrated embodiment, the piston230is disposed radially between the outer sleeve210and the mandrel216. The piston230may include a plurality of annular piston seals232(e.g., O-rings) configured to form seals between the piston230and the radially inner sleeve surface214, as well as between the piston230and the radially outer mandrel surface220. The plurality of annular piston seals232may be configured to block fluid flow from an inner side234of the piston230to an outer side236of the piston230such that the piston230may seal the setting chamber228from the wellbore104. The piston230may include at least one radially inner piston recess238and at least one radially outer piston recess240configured to house the plurality of annular piston seals232. Moreover, as illustrated, the piston230is disposed axially between the setting port224and at least one radially actuatable component206of the hydraulic set packer system200. The piston230is configured to move (e.g., slide) axially along the mandrel216in response to a pressure in the setting chamber228exceeding a threshold setting pressure (e.g., a setting pressure) to set the hydraulic set packer system200. That is, the setting pressure is configured to drive the piston230from a pre-set position to a setting position in contact with the at least one radially actuatable component206of the hydraulic set packer system200. Further, the setting pressure may exert a force on the piston230such that the piston230may drive at least one radially actuatable component206to actuate in a radially outward direction246to engage a wellbore104wall of the wellbore104(e.g., to drive the at least one radially actuatable component206from the collapsed position to an expanded position). Moreover, pressure isolation assembly202may be disposed radially between the outer sleeve210and the mandrel216to seal the second axial end252of the setting chamber228opposite the piston230. Sealing the setting chamber228from the wellbore104may reduce a pressure needed in the central bore222to achieve the threshold setting pressure for driving the piston230to set the hydraulic set packer system200. In the illustrated embodiment, the pressure isolation assembly202includes a pressure isolation ring254having a chamber sealing portion256, an inlet portion258, and a port sealing portion260. The chamber sealing portion256may be configured to seal the second axial end252of the setting chamber228. The chamber sealing portion256may be positioned outside of the setting port224. That is, the setting port224may be positioned axially between the piston230and the chamber sealing portion256such that fluid may enter the setting chamber228between the piston230and the chamber sealing portion256. Moreover, the pressure isolation assembly202may include a plurality of isolation seals262configured to seal a radially outer sealing chamber surface264and a radially inner sealing chamber surface266of the chamber sealing portion256against the radially inner sleeve surface214and the radially outer mandrel surface220. Further, the chamber sealing portion256may include at least one radially inner chamber sealing recess268and at least one radially outer chamber sealing recess270configured to house the plurality of isolation seals262. The inlet portion258of the pressure isolation ring254includes a radial through-bore272. In the pre-set state of the hydraulic set packer system200, the pressure isolation assembly202(e.g., the pressure isolation ring254) is disposed in a first position with the radial through-bore272aligned with the setting port224such that fluid may flow into the setting chamber228from the central bore222. The radial through-bore272may extend from a radially inner inlet surface276of the pressure isolation ring254to a radially outer inlet surface278of the pressure isolation ring254. In some embodiments, the radially outer inlet surface278is configured to interface with the radially outer mandrel surface220to provide additional sealing for the setting chamber228. However, the radially outer inlet surface278of the pressure isolation ring254is disposed radially inward from the radially inner sleeve surface214such that an inlet portion gap282is formed between the inlet portion258and the outer sleeve210. As illustrated, the inlet portion gap282forms a portion of the setting chamber228. The pressure isolation ring254also includes the port sealing portion260. In the first position of the pressure isolation assembly202(e.g., the pressure isolation ring254) the port sealing portion260may be disposed between the setting port224and the piston230. The port sealing portion260has a radially inner port sealing surface282and a radially outer port sealing surface284. The radially outer port sealing surface284may also be disposed radially inward from the radially inner sleeve surface214such that a port sealing portion gap286is formed between the inlet portion258and the outer sleeve210. The port sealing portion gap286may also form a portion of the setting chamber228. In some embodiment, the radially outer port sealing surface284may be aligned with the radially outer inlet surface278such that the inlet portion gap282and the port sealing portion gap286are aligned and have a same radial width. However, in some embodiments, the radially outer port sealing surface284may be radially offset from the radially outer inlet surface278. FIG.2Billustrates an embodiment of the hydraulic set packer system200in a set state. Once the hydraulic set packer system200is in the desired position in the wellbore104, hydraulic pressure is pumped into the conveyance106to set the hydraulic set packer system200. Specifically, as illustrated, the piston230is configured to move to the setting position in response to a pressure in the setting chamber228at or exceeding a threshold setting pressure (e.g., the setting pressure). Further, with the piston230in the setting position, the setting pressure may exert a force on the piston230such that the piston230may drive at least one radially actuatable component206to actuate in a radially outward direction246to engage a wellbore104wall of the wellbore104and set the hydraulic set packer system200. In the illustrated embodiment, the hydraulic set packer system200includes a shear pin290configured to restrain axial movement of the pressure isolation assembly202with respect to the mandrel216. The shear pin290is configured to sustain the setting pressure such that the pressure isolation assembly202remains secured in the first position as the piston230moves from the pre-set position to the setting position. However, after the hydraulic set packer system200is set, pressure in the setting chamber228may be increased above the setting pressure due to the piston230being secured in the setting position (i.e., the piston230cannot move to expand the setting chamber228, thereby, reducing pressure in the setting chamber228or holding the pressure in the setting chamber228at the setting pressure). Thus, continued fluid communication with the central bore222, via the setting port224and the radial through-bore272, may increase the pressure in the setting chamber228to a pressure in the setting chamber228at or exceeding a threshold sealing pressure (e.g., a sealing pressure). The shear pin290may be configured to shear in response to the sealing pressure. FIG.2Cillustrates an embodiment of the hydraulic set packer system200in a sealed state. As set forth above, after setting the hydraulic set packer system200, a sealing pressure in the setting chamber228may shear the shear pin290restraining axial movement of the pressure isolation assembly202such that the pressure isolation assembly202may move from the first position (shown inFIGS.2A and2B) to a second position and transition the hydraulic set packer system200to a sealed state. In particular, once the shear pin290is sheared, the fluid pressure in the setting chamber228may drive the pressure isolation assembly202from the first position to the second position. In the illustrated embodiment, the hydraulic set packer system200includes a pressure isolation assembly stop294to block axial movement of the pressure isolation assembly202at the second position via contact with the pressure isolation assembly202. The pressure isolation assembly stop294may be secured to the mandrel216and extend into an annulus296between the mandrel216and the outer sleeve210. In another embodiment, the pressure isolation assembly stop294may be secured to the outer sleeve210and extend into the annulus296between the mandrel216and the outer sleeve210. Further, in some embodiments, the pressure isolation assembly stop294may be secured to both the mandrel216and the outer sleeve210. Moreover, as illustrated, with the pressure isolation assembly202(e.g., the pressure isolation ring254) in the second position, the port sealing portion260of the pressure isolation ring254is axially aligned with the setting port224to seal the setting port224and block fluid communication between the central bore222and the setting chamber228. Indeed, in the second position, the inlet portion258is axially offset from the setting port224such that the radial through-bore272is misaligned with the setting port224and fluid may no longer enter the setting chamber228via the inlet portion258. Instead, the radially inner port sealing surface282of the port sealing portion260of the pressure isolation ring254is axially aligned with the setting port224. The radially inner port sealing surface282may have a diameter substantially similar to a diameter of the radially outer mandrel surface220such that the radially inner port sealing surface282may contact and/or seal against portions of the radially outer mandrel surface220adjacent the setting port224. Further, the port sealing portion260may include a plurality of port seals298configured to seal fluid communication between the setting port224and the setting chamber228. The radially inner port sealing surface282of the port sealing portion260of the pressure isolation ring254may include at least one first port sealing recess201and at least one second port sealing recess203configured to house the plurality of plurality of port seals298. The at least one first port sealing recess201and the at least one second port sealing recess203may be positioned on the radially inner port sealing surface282such that they are disposed on opposite radial sides of the setting port224with the pressure isolation ring254in the second position. Moreover, the hydraulic set packer system200may further include a biasing mechanism205to hold the pressure isolation assembly202in the second position. Once the setting chamber228is sealed from the central bore222, pressure in the setting chamber228may reduce over time, such that pressure in the setting chamber228may no longer hold the pressure isolation ring254in the second position against the pressure isolation assembly stop294. However, the biasing mechanism205may be configured to provide sufficient force against the pressure isolation ring254to hold the pressure isolation ring254in the second position. In the illustrated embodiment, the biasing mechanism205includes a compression spring207disposed between the pressure isolation assembly202and a spring block209. However, the biasing mechanism205may include any suitable biasing mechanism205. As illustrated, the compression spring207is disposed between a port sealing portion260of the pressure isolation assembly202and the spring block209. In some embodiments, the biasing mechanism205is configured to help drive the pressure isolation assembly202from the first position in a direction toward the second position. The compression spring207may be compressed in the first position such that the compression spring207exerts a force on the pressure isolation assembly202in the first position. Once the shear pin290is sheared, the force from the compression spring207drives or helps drive the pressure isolation assembly202from the first position in a direction toward the second position. The hydraulic set packer system200may further include a pressure release port211for the setting chamber228. In the illustrated embodiment, the outer sleeve210includes the pressure release port211. The pressure release port211extends through a radial sleeve wall213of the outer sleeve210to provide fluid communication between the setting chamber228and the wellbore104. With the pressure isolation ring254in the first position, the sealing chamber portion is configured to seal the pressure release port211such that fluid pressure may increase to the setting pressure and the sealing pressure (shown inFIG.2A). However, after the hydraulic set packer system200is set, the setting pressure and/or sealing pressure no longer needs to be maintained in the setting chamber228. Thus, as illustrated, the hydraulic set packer system200may include the pressure release port211positioned along the outer sleeve210such that the pressure release port211may be open in the second position to release pressure to the wellbore104. That is, in the second position, the inlet portion gap280formed between the inlet portion258and the outer sleeve210is aligned with the pressure release port211such that the setting chamber228is in fluid communication with the wellbore104. FIG.3illustrates cross-sectional view of an embodiment of the hydraulic set packer system200, in accordance with some embodiments of the present disclosure. As set forth above with respect toFIG.2C, the hydraulic set packer system200may include a compression spring207to hold the pressure isolation ring254in the second position against the pressure isolation assembly stop294. However, in the illustrated embodiment, a wellbore pressure is configured to hold pressure isolation ring254against the pressure isolation assembly stop294in the second position. As the sealing pressure in the setting chamber228drives the pressure isolation ring254to move to the second position, the port sealing portion260of the pressure isolation ring254is configured to align with the setting port224to seal fluid communication between the setting port224and the setting chamber228. Further, in the second position, the inlet portion258of the pressure isolation ring254is configured to align with the pressure release port211such that the sealing pressure in the setting chamber228may be released into the wellbore104. As such, a pressure (e.g., a wellbore104pressure) in the setting chamber228may equalize with a pressure in the wellbore104environment. As set forth above, the wellbore104pressure may be configured to hold the pressure isolation ring254in the second position such that the port sealing portion260of the pressure isolation ring254maintains the seal that isolates the setting chamber228from the central bore222. FIG.4illustrates a cross-sectional view of the hydraulic set packer system200for retaining a sealing pressure in a setting chamber228via a pressure isolation ring254, in accordance with some embodiments of the present disclosure. As set forth above with respect toFIG.3, the hydraulic set packer system200may include the pressure release port211positioned along the outer sleeve210such that the sealing pressure (e.g., for driving the pressure isolation ring254from the first position to the second position) may be released to the wellbore104in the second position. In the illustrated embodiment, the pressure release port211is positioned along the outer sleeve210at a same radial plane as at least one shear screw hole400. After the shear pins290are sheared, the pressure isolation ring254moves to the second position, and the sealing pressure in the setting chamber228may be released into the wellbore104. FIGS.5A and5Billustrate cross-sectional views of the hydraulic set packer system200having a pressure isolation assembly202secured to an outer sleeve210, in accordance with some embodiments of the present disclosure. In particular,FIG.5Aillustrates an embodiment of the hydraulic set packer system200in the pre-set state. As set forth above, in the pre-set state, the at least one radially actuatable component206(shown inFIG.2A-2C) of the hydraulic set packer system200is in the collapsed position such that the hydraulic set packer system200may be run-in-hole. Further, the hydraulic set packer system200includes the outer sleeve210having the substantially hollow cylindrical shape with the radially outer sleeve surface212and the radially inner sleeve surface214. The outer sleeve210may also include a sleeve shoulder portion500extending radially inward from the outer sleeve210. The sleeve shoulder portion500may be configured to interface with the radially outer mandrel surface220of the mandrel216. Further, in the illustrated embodiment, the hydraulic set packer system200includes a first locking feature502(e.g., shear pin, set screw, etc.). The first locking feature502is configured to secure the outer sleeve210to the mandrel216in the pre-set state. In the illustrated embodiment, the first locking feature502is configured to extend radially inward from the sleeve shoulder portion500to secure the outer sleeve210to the mandrel216. However, the first locking feature502may extend from any portion of the outer sleeve210to secure the outer sleeve210to the mandrel216. Moreover, the mandrel216extends through the outer sleeve210and has the central bore222for conveying fluid from the surface through the hydraulic set packer system200. Further, the setting port224of the mandrel216extends through the radial wall226of the mandrel216(e.g., extending between the radially inner mandrel surface218and the radially outer mandrel surface220). The setting port224is configured to provide fluid communication from the central bore222of the mandrel216to the setting chamber228. Additionally, the mandrel216may include a mandrel shoulder portion504extending radially outward from the radially outer mandrel surface220. The mandrel shoulder portion504may be configured to interface with the sleeve shoulder portion500during operation of the hydraulic set packer system200. The hydraulic set packer system200further includes the piston230. In the illustrated embodiment, the setting chamber228is defined between the mandrel216and the outer sleeve210in the radial direction and between the piston230and the sleeve shoulder portion500in the axial direction. That is, the piston230and the sleeve shoulder portion500may each be sealed against the mandrel216and the outer sleeve210to fluidly isolate the setting chamber228from the wellbore104. Further, the piston230and the sleeve shoulder portion500may include respective recesses (e.g., the radially inner piston recess238, the radially outer piston recess240, and sleeve shoulder recesses506) configured to hold corresponding seals (e.g., annular piston seals232and sleeve shoulder seals508) for sealing the piston230and the sleeve shoulder portion500against the mandrel216and the outer sleeve210. Moreover, in the pre-set state, the piston230may be secured to the outer sleeve210via a second locking feature510(e.g., shear pin, set screw, etc.). For example, the second locking feature510may include a shear pin extending into a sleeve locking recess512of the outer sleeve210and a piston locking recess514in the piston230to restrain axial movement between the piston230and the outer sleeve210. The second locking feature510is configured to release the piston230to move axially with respect to the outer sleeve210in response to the setting pressure (e.g., a pressure at or above the threshold setting pressure) in the setting chamber228. In some embodiments, the second locking feature510may be configured to shear to release the piston230. The released piston230is configured to set the hydraulic set packer system200. That is, with the piston230released, the setting pressure is configured to drive the piston230from a pre-set position to a setting position in contact with the at least one radially actuatable component206(shown inFIGS.2A-2C) of the hydraulic set packer system200. Further, the setting pressure may exert a force on the piston230such that the piston230may drive at least one radially actuatable component206to actuate in a radially outward direction246to engage a wellbore104wall of the wellbore104(e.g., to drive the at least one radially actuatable component206from the collapsed position to an expanded position). Moreover, as set forth above, the hydraulic set packer system200includes the first locking feature502(e.g., shear pin) configured to secure the outer sleeve210to the mandrel216in the pre-set state. The first locking feature502is configured to sustain the setting pressure such that the outer sleeve210remains secured to the mandrel216as the piston230moves from the pre-set position to the setting position. However, after the hydraulic set packer system200is set, pressure in the setting chamber228may be increased above the setting pressure due to the piston230being secured in the setting position (i.e., the piston230cannot move to expand the setting chamber228, thereby, reducing pressure in the setting chamber228or holding the pressure in the setting chamber228at the setting pressure). Thus, continued fluid communication with the central bore222, via the setting port224, may increase the pressure in the setting chamber228to a pressure in the setting chamber228at or exceeding a threshold sealing pressure (e.g., the sealing pressure). The first locking feature502may be configured to release (e.g., shear) in response to the sealing pressure such that the outer sleeve210may move axially with respect to the mandrel216. The hydraulic set packer system200further includes the pressure isolation ring254. In the illustrated embodiment, the pressure isolation ring254is rigidly coupled to the radially inner sleeve surface214of the outer sleeve210and disposed within the setting chamber228. In some embodiments, the pressure isolation ring254may be threaded to the outer sleeve210. However, in other embodiments, the pressure isolation ring254may be rigidly coupled to the outer sleeve210via any suitable fastener. Moreover, as the pressure isolation ring254is rigidly coupled to the outer sleeve210, the pressure isolation ring254may be configured to move axially with respect to the mandrel216as the outer sleeve210moves. In the illustrated embodiment, with the outer sleeve210secured to the mandrel216via the first locking feature502, the pressure isolation ring254is disposed in the first position. In the first position, the pressure isolation ring254is disposed between the setting port224and the piston230. The pressure isolation ring254may include an axial through-bore516such that piston230is in fluid communication with the setting port224in the first position. However, as set forth in detail below, the pressure isolation ring254is configured to move from the first position to the second position after the piston230moves to the set position. The mandrel shoulder portion504may be positioned to interface with the sleeve shoulder portion500to stop axial movement of the outer sleeve210with the pressure isolation ring254disposed in the second position. FIG.5Billustrates an embodiment of the hydraulic set packer system200in the sealed state. In the sealed state, the piston230, having set the hydraulic set packer system200, is disposed in the setting position. Further, the pressure isolation ring254is disposed in the second position. In the second position, the pressure isolation ring254is axially aligned with the setting port224such that the pressure isolation ring254may block fluid communication between the setting port224and the setting chamber228. A radially inner ring surface518of the pressure isolation ring254may have a diameter substantially similar to a diameter of the radially outer mandrel surface220such that the radially inner surface of the pressure isolation ring254may contact and/or seal against portions of the radially outer mandrel surface220adjacent the setting port224. Further, the pressure isolation ring254may include a first isolation seal520and a second isolation seal522disposed on opposite axial sides of the setting port224to seal the setting chamber228from the setting port224and block fluid communication between the setting port224and the setting chamber228. FIGS.6A-6Cillustrate cross-sectional views of the hydraulic set packer system200having the pressure isolation assembly202with an isolation piston620, in accordance with some embodiments of the present disclosure. Specifically,FIG.6Aillustrates an embodiment of the hydraulic set packer system200in the pre-set state. As set forth above, the hydraulic set packer system200includes the outer sleeve210with the mandrel216extending through the outer sleeve210. The mandrel216has the central bore222for conveying fluid from the surface through the hydraulic set packer system200. As set forth above, the mandrel216includes the setting port224extending through the radial wall226of the mandrel216. In the illustrated embodiment, the mandrel216further includes a piston seal assembly602in fluid communication with the setting port224. The piston seal assembly602may be formed via a protrusion extending radially outward from the radially outer mandrel surface220of the mandrel216. That is, the piston seal assembly602may be a feature of the mandrel216. However, in some embodiments, the piston seal assembly602may be coupled to the mandrel216via a fastener. Moreover, as illustrated, an intake opening604of the piston seal assembly602is axially aligned with the setting port224such that the piston seal assembly602may be in fluid communication with the central bore222via the setting port224. The piston seal assembly602may receive the fluid communication via the intake opening604into a stepped through bore606extending through the piston seal assembly602. The stepped through-bore606may include at least two portions having distinct diameters along a length of the stepped through-bore606such that a shoulder700(shown inFIG.7) is formed at each step/transition between adjacent portions. The stepped through-bore606is fluidly coupled with the setting chamber228, such that fluid communication between the setting chamber228and the central bore222is established through the setting chamber228, the intake opening604, and the stepped through-bore606. Moreover, the hydraulic set packer system200further includes the piston230. In the pre-set state, the piston230may be disposed in the pre-set position with at least a portion of the piston230disposed between the mandrel216and the outer sleeve210. In some embodiments, the piston230may define a first axial end250of the setting chamber228. As illustrated, the piston230may each be sealed against the mandrel216and the outer sleeve210to fluidly isolate the first axial end250of the setting chamber228from the wellbore104. Further, the piston230may include a plurality of recesses (e.g., the radially inner piston recess238and the radially outer piston recess240) configured to hold corresponding annular piston seals232for sealing the piston230against the mandrel216and the outer sleeve210. A second axial end252of the setting chamber228may be defined by a guide feature608of the hydraulic set packer system200. As illustrated, the guide feature608may comprise an annular ring disposed between the mandrel216and the outer sleeve210on an opposite side of the piston seal assembly602. The guide feature608may be secured to the mandrel216, the outer sleeve210, or some combination thereof, such that the guide feature608remains secured as the piston230sets the hydraulic set packer system200. Further, the guide feature608may each be sealed against the mandrel216and the outer sleeve210to fluidly isolate the second axial end252of the setting chamber228from the wellbore104. Further, the guide feature608may include a plurality of guide recesses610configured to hold corresponding guide seals612for sealing the guide feature608against the mandrel216and the outer sleeve210. Moreover, a portion of the radially inner sleeve surface214of the outer sleeve210and a portion of the radially outer mandrel surface220of the mandrel216may define respective radial ends of the setting chamber228. Pressure in the setting chamber228is configured to set and seal the hydraulic set packer system200. Indeed, the piston230is configured to move axially with respect to the outer sleeve210to set the hydraulic set packer system200in response to the setting pressure (e.g., a pressure at or above the threshold setting pressure) in the setting chamber228. That is, the setting pressure is configured to drive the piston230from a pre-set position to the setting position in contact with the at least one radially actuatable component206of the hydraulic set packer system200. Further, the setting pressure may exert a force on the piston230such that the piston230may drive at least one radially actuatable component206to actuate in a radially outward direction246to engage a wellbore wall of the wellbore104(e.g., to drive the at least one radially actuatable component206from the collapsed position to an expanded position). Moreover, as set forth above, the hydraulic set packer system200includes the guide feature608. In a secured state (i.e., secured to the mandrel216, the outer sleeve210, or some combination thereof), the guide feature608blocks movement of an isolation piston620and/or biasing mechanism205. The guide feature608may be secured via at least one fastener614(e.g., shear pin) configured to sustain the setting pressure such that the guide feature608remains secured to the mandrel216as the piston230moves from the pre-set position to the setting position. However, after the hydraulic set packer system200is set, pressure in the setting chamber228may be increased above the setting pressure due to the piston230being secured in the setting position (i.e., the piston230cannot move to expand the setting chamber228, thereby, reducing pressure in the setting chamber228or holding the pressure in the setting chamber228at the setting pressure). Thus, continued fluid communication with the central bore222, via the setting port224, the intake opening604, and the stepped through-bore606, may increase the pressure in the setting chamber228to a pressure in the setting chamber228at or exceeding a threshold sealing pressure (e.g., the sealing pressure). The fastener614may be configured to shear in response to the sealing pressure to release the guide feature608such that the guide feature608may move axially with respect to the mandrel216. In a released state, the guide feature608also releases the biasing mechanism205. The biasing mechanism205is configured to drive the isolation piston620from the first position to the second position. In the illustrated embodiment, the guide feature608is disposed between the biasing mechanism205and the isolation piston620. Further, the isolation piston620may be coupled to the guide feature608such that the isolation piston620may move axially with the guide feature608. Thus, the biasing mechanism205may be configured to drive the guide feature608axially along the mandrel216to drive the isolation piston620from the first position to the second position. The biasing mechanism205may include the compression spring207having a first spring end616coupled to the guide feature608and a second spring end618coupled to the spring block209. The compression spring207may be compressed with the isolation piston620in the first position. That is, the compression spring207may be compressed with the guide feature608in the secured state such the compression spring207expand to drive the guide feature608and isolation piston620when the guide feature608is released. In some embodiments, the biasing mechanism205may be coupled directly to the isolation piston620. The isolation piston620is configured to move axially with respect to the mandrel216from the first position to the second position to seal the setting port224. However, in the first position, the isolation piston620is axially offset from the setting port224. In the illustrated embodiment, the isolation piston620is disposed partially within the stepped through-bore606of the piston seal assembly602. The stepped through-bore606includes a wide bore portion622and a narrow bore portion624, with the wide bore portion622having a larger inner diameter than the narrow bore portion624. The wide bore portion622and the narrow bore portion624may be substantially coaxial. Further, the wide bore portion622extends axially across a portion of the piston seal assembly602from a biasing side626of the piston seal assembly602. The narrow bore extends from a piston side628of the piston seal assembly602to the wide bore portion622such that the narrow bore portion624is in fluid communication with the wide bore portion622. The intake opening604may be in fluid communication with the wide bore portion622. Moreover, in the first position, the isolation piston620is disposed in the wide bore portion622of the stepped through-bore606. An outer isolation piston surface630of the isolation piston620may have a substantially similar diameter to an inner wide bore surface632of the wide bore portion622such that the isolation piston620may radially seal against the inner wide bore surface632. Indeed, the isolation piston620may block fluid from flowing out of the biasing side626of the piston seal assembly602via the wide bore portion622such that the fluid flow through the intake opening604may pass into the wide bore portion622and flow through the narrow bore portion624toward the setting chamber228. FIG.6Billustrates an embodiment of the hydraulic set packer system200in the sealed state. In the sealed state, the piston230, having set the hydraulic set packer system200, is disposed in the setting position. Further, the isolation piston620is disposed in the second position. In the second position, the isolation piston620is axially aligned with the intake opening604in the wide bore portion622and the setting port224such that the isolation piston620may block fluid communication between the central bore222and the setting chamber228. As set forth above, the outer isolation piston surface630of the isolation piston620may seal against portions of the inner wide bore surface632adjacent the intake opening604and the setting port224via vee packing. Alternatively, the isolation piston may house a sealing system (e.g., O-rings) having a diameter substantially similar to the inner wide bore surface632of the wide bore portion622to seal against portions of the inner wide bore surface632adjacent the intake opening604and the setting port224. As such, the isolation piston620may block fluid communication between the central bore222and the setting chamber228. FIG.6Cillustrates cross-sectional view of the isolation assembly202having the isolation piston620. In the illustrated embodiment, the isolation piston620is disposed in the second position. As set forth above, in the second position, the isolation piston620is axially aligned with the intake opening604in the wide bore portion622and the setting port224such that the isolation piston620may block fluid communication between the central bore222and the setting chamber228. Specifically, the outer isolation piston surface630of the isolation piston620may contact and/or seal against portions of the inner wide bore surface632of the wide bore portion622adjacent the intake opening604and the setting port224to form a seal around the intake opening604such that the isolation piston620may block fluid communication between the central bore222and the setting chamber228. Further, as illustrated, the isolation piston620may be configured to seal the wide bore portion622from the narrow bore portion624of the stepped through-bore606. In particular, a shoulder700of the stepped through-bore606may be formed at the transition from the wide bore portion622to the narrow bore portion624due to the wide bore portion622and the narrow bore portion624having different inner diameters. In the second position, an axial sealing face700of the isolation piston620is configured to contact the shoulder700with the isolation piston620in the second position. The axial sealing face702of the isolation piston620is configured to seal against the shoulder700of the stepped through-bore606, via the contact, to form an additional seal between the central bore222and the setting chamber228. In some embodiment, the piston seal assembly602and the isolation piston620may include metal material such that driving the axial sealing face702against the shoulder700forms metal to metal sealing. Accordingly, the present disclosure may provide systems for isolating a setting chamber of a hydraulically actuated tool and may include any of the various features disclosed herein, including one or more of the following statements. Statement 1. A hydraulic set packer system may comprise an outer sleeve; a mandrel extending through the outer sleeve; a setting port extending through a radial wall of the mandrel, the setting port configured to provide fluid communication from a central bore of the mandrel to a setting chamber formed between the outer sleeve and the mandrel; a piston configured to move axially along the mandrel in response to a setting pressure in the setting chamber, the piston configured to drive at least one radially actuatable component to actuate in a radial direction to engage a wellbore wall; and a pressure isolation assembly disposed in the setting chamber, the pressure isolation assembly configured to move axially with respect to the mandrel from a first position to a second position to seal the setting port. Statement 2. The system of statement 1, wherein the pressure isolation assembly comprises a pressure isolation ring having a radial through-bore, wherein the radial through-bore is axially aligned with the setting port in the first position such that fluid may flow into the setting chamber from the central bore. Statement 3. The system of statement 1 or statement 2, further comprising a shear pin configured to restrain axial movement of the pressure isolation assembly with respect to the mandrel, and wherein the shear pin is configured to shear in response to pressure in the setting chamber exceeding a threshold setting pressure. Statement 4. The system of any preceding statement, further comprising a biasing mechanism configured to drive the pressure isolation assembly from the first position in a direction toward the second position. Statement 5. The system of any preceding statement, wherein the biasing mechanism comprises a compression spring disposed between the pressure isolation assembly and a spring block, and wherein the compression spring is compressed in the first position. Statement 6. The system of any preceding statement, wherein the outer sleeve comprises a pressure release port extending through a radial wall of the outer sleeve, wherein the pressure release port is configured to provide fluid communication between the setting chamber and a wellbore. Statement 7. The system of any preceding statement, wherein the pressure isolation assembly is configured to seal the pressure release port in the first position and open the pressure release port in the second position. Statement 8. The system of any preceding statement, further comprising a pressure isolation assembly stop secured to the mandrel, wherein pressure isolation assembly stop is configured contact the pressure isolation assembly to block axial movement of the pressure isolation assembly at the second position. Statement 9. The system of any preceding statement, wherein the piston is a least partially disposed within the setting chamber to seal a first side of the setting chamber from the wellbore. Statement 10. The system of statement 1 or statements 3-9, wherein the pressure isolation assembly comprises a pressure isolation ring having an axial through-bore. Statement 11. The system of statement 1 or statements 3-9, wherein the pressure isolation assembly comprises an isolation piston, wherein isolation piston configured to move axially into a piston seal assembly aligned with the setting port to seal the setting port. Statement 12. A hydraulic set packer system may comprise an outer sleeve; a mandrel extending through the outer sleeve and secured to the outer sleeve via a first locking feature; a setting port extending through a radial wall of the mandrel, the setting port configured to provide fluid communication from a central bore of the mandrel to a setting chamber formed between the outer sleeve and the mandrel; a piston secured to the outer sleeve via a second locking feature that is configured to release the piston to move axially with respect to the outer sleeve in response to a setting pressure in the setting chamber, the piston configured to drive at least one radially actuatable component to actuate in a radial direction to engage a wellbore wall; and a pressure isolation ring rigidly coupled to a radially inner surface of the outer sleeve and disposed within the setting chamber, the pressure isolation ring configured to move axially with respect to the mandrel from a first position to a second position to seal the setting port. Statement 13. The system of statement 12, wherein the pressure isolation ring is disposed between the setting port and the piston in the first position, and wherein the pressure isolation ring comprises an axial through-bore such that piston is in fluid communication with the setting port in the first position. Statement 14. The system of statement 12 or statement 13, wherein the pressure isolation ring is axially aligned with the setting port in the second position, and wherein the pressure isolation ring comprises a first seal and a second seal disposed on opposite axial sides of the setting port to seal the setting chamber from the setting port. Statement 15. The system of any of statements 12-14, wherein the second locking feature comprises a shear pin extending into a first sleeve recess of the outer sleeve and a piston recess in the piston to restrain axial movement between the piston and the outer sleeve, wherein the second locking feature is configured to shear to release the piston to move axially with respect to the outer sleeve in response to the setting pressure in the setting chamber. Statement 16. The system of any of statements 12-15, wherein the first locking feature comprises a shear pin extending into a sleeve recess of the outer sleeve and a mandrel recess in the mandrel to restrain axial movement between the mandrel to the outer sleeve, wherein the first locking feature is configured to shear to release the outer sleeve with respect to the mandrel in response to a sealing pressure in the setting chamber, and wherein the sealing pressure is higher than the setting pressure. Statement 17. A hydraulic set packer system, comprising: an outer sleeve; a mandrel extending through the outer sleeve; a setting port extending through a radial wall of the mandrel, the setting port configured to provide fluid communication from a central bore of the mandrel to a setting chamber formed between the outer sleeve and the mandrel, and wherein the mandrel includes a piston seal assembly to receive the fluid communication via the setting port into a stepped through-bore extending axially through the piston seal assembly and direct the fluid communication into the setting chamber; a piston configured to move axially along the mandrel in response to a setting pressure in the setting chamber, wherein the piston is configured to drive at least one radially actuatable component to actuate in a radial direction to engage a wellbore wall; and an isolation piston disposed in the setting chamber, wherein the isolation piston is configured to move axially with respect to the mandrel from a first position to a second position to seal the setting port, wherein the isolation piston is at least partially disposed in the stepped through-bore in the second position, and wherein a radially outer surface of the isolation piston is configured to seal the setting bore from the stepped through-bore; a biasing mechanism configured to drive the isolation piston from the first position to the second position; and a guide feature configured to block movement of the biasing mechanism in a secured state and release the biasing mechanism to drive the isolation piston in the released state, wherein the guide feature is configured to transition from the secured state to the released state in response to a sealing pressure in the setting chamber, wherein the sealing pressure is higher than the setting pressure. Statement 18. The system of statement 17, wherein an axial sealing face of the isolation piston is configured to seal against a shoulder of the stepped through-bore to form an additional seal between the setting port and the setting chamber, the shoulder formed between a narrow portion of the stepped through-bore having a first diameter and a wide portion of the stepped through-bore having a second diameter. Statement 19. The system of statement 17 or statement 18, wherein the biasing mechanism comprises a compression spring, and wherein the compression spring is compressed in the first position. Statement 20. The system of any of statements 17-19, wherein the guide feature comprises at least one shear pin configured to hold the guide feature in the secured state, and wherein the setting pressure in the setting chamber is configured to shear the at least one shear pin to transition the guide feature from the secured state to the released state. To facilitate a better understanding of the present invention, the following examples of certain aspects of some embodiments are given. In no way should the following examples be read to limit, or define, the entire scope of the disclosure. For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited. Therefore, the present embodiments are 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 embodiments may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Although individual embodiments are discussed, all combinations of each embodiment are contemplated and covered by the disclosure. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. 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. | 51,509 |
11859464 | DETAILED DESCRIPTION Many techniques and tools have been developed to perform batch drilling. This methodology involves moving a rig to successive locations on the same pad site to drill multiple wells, as shown inFIGS.6and7. Batch drilling enables the subsequent cementing process at each well to be performed “offline,” i.e., without the rig in place because it has moved to the next well site. By taking (surface/intermediate/production) casing cementing off of the critical path of the drilling rig, the overall cycle time is significantly reduced to realize cost savings. Currently, there is no intermediate casing mechanical barrier at surface during offline cementing operations as the rig is moved off of the well to resume batch drilling the next well. Therefore, there are significant health and safety risks to personnel when no barrier safeguards are provided at the surface. It is thus desirable to develop a new mechanical wellhead barrier that can quickly interface with the cement head when surface, intermediate and production casings are being installed that will be a standardized device for batch drilling and offline cementing operations. To drill the well to surface, intermediate or production depth with the drilling rig, a blowout preventer (BOP) is installed on the wellhead. A BOP (not explicitly shown) is a valve assembly that encases the wellhead at the surface. It includes a series of valves, rams, and seals that restrict the pressurized wellbore fluid from breaching the well and getting to the surface. The BOP is typically left in place during the cementing process as the rig is moved away to the next well site. As shown inFIG.1, a casing hanger10is installed on the well casing support shoulder12or casing head. The casing hanger10is used to support, surface or intermediate casing14that is inserted and dropped into the well. An isolation sleeve16is then installed on top of the casing hanger10and a lock ring is engaged using a running tool. The isolation sleeve16, also referred to as the cementing spool, includes a dummy hanger22that is in fluid communication with the casing hanger10and the casing14in the wellbore. The isolation sleeve/cementing spool16further has an inlet24and an outlet26that provides access to the bore annulus. Valves28and30, such as wing valves, are disposed at the cement inlet24and outlet26to control cement flow. The isolation sleeve/cementing spool16enables the cementing process to be performed offline by providing a pressure control interface at the wellhead. A TIW (ball-type) valve32is installed atop the isolation sleeve/cementing spool16with a quick connector34(seeFIG.4) that enables the use of low torque drive screws36to quickly secure a conduit35to the cementing head (not explicitly shown) thereon to inject the cementing slurry down the well and up the annulus to affix the casing in place. The quick connector34shown inFIG.4is preferably a Weir® Quick Connector (WQC) or a quick connect BOP adapter, that is designed to provide a mechanism for connecting the BOP to the wellhead. This quick connector speeds up the process of connecting to the wellhead to provide a safer and more reliable way to provide a pressure-tight metal seal between critical service equipment. The body of the quick connector provides robust guidance onto the wellhead and simplifies this operation. FIG.5is an illustration of an exemplary cementing setup. To perform offline cementing, the casing hanger10is placed in position on the support shoulder12. The isolation sleeve16is then landed on top of the casing hanger10and the lock ring is engaged. The TIW valve32is installed. Offline cementing proceeds. At the completion of the cementing process including the installation of the cement plug, the cementing head is removed, the TIW valve32is dosed, and the blowout preventer (BOP) stack can be safely nippled down (taken apart and removed). Referring toFIGS.2and3, after the cementing process is completed, the cementing spool/isolation sleeve16and cementing head are removed. A primary seal40is then installed and the lock ring42is engaged to secure the primary seal40in place. A back pressure valve (BPV) is then installed in the casing hanger10. Some of the desirable characteristics of the system described herein include: 1) provide a mechanical barrier at surface; 2) can be set and removed without use of the rig or wireline; 3) the ability to interface with, e.g., 5½″, 7⅝″, 8⅝″, 9⅝″, and 13⅜″ casings; 4) interface with offline cementing operations; and 5) ease of installation and removal resulting in time savings. The drilling and cementing procedure according to the present disclosure can be generalized as follows: 1) Spudding: Drill a cellar up to the depth of 15 ft to provide a pathway for wellhead equipment and casing strings to be running pipe in the hole (RIH). 2) Drill another larger hole (Conductor hole) AND RIH conductor pipe through the cellar by hammering. 3) Use a pilot bit to drill smaller diameter of the hole so that the larger bit cannot get slippage. 4) 1st Stage: Continue the drilling further to the depth of surface casing (20″ O.D) and RIH surface casing with casing head housing (CHH). 5) Cement in place the surface casing. 6) 2nd Stage: Drilling continues to the depth of intermediate casing (13⅜ ″) and RIH intermediate casing. 7) Set Casing Head Spool (CHS) on Casing head housing and cement in place. Run casing hanger on CHS. 8) 3rd Stage: Continue the drilling process up to the depth of production casing (9⅝″) and run casing hanger. Cement the casing and RIH tubing hanger setting (THS) on CHS and perforate (optional: if required). 9) 4th Stage: Run tubing components and space out (pull out of the hole (POOH) the assembly to add the length of pipes i.e. adding spacers) to meet the required length of string. 10) Run tubing with tubing hanger on THS. 11) Set Packer. 12) Set BPV (Back Pressure Valve) on tubing hanger. 13) Remove the blowout preventer (BOP) and set X-mas tree. 14) Conduct TCP (Tubing Conveyed Perforation) if perforation not done. The features of the present invention which are believed to be novel are set forth below with particularity in the appended claims. However, modifications, variations, and changes to the exemplary embodiments described above will be apparent to those skilled in the art, and the system and method described herein thus encompasses such modifications, variations, and changes and are not limited to the specific embodiments described herein. | 6,530 |
11859465 | DETAILED DESCRIPTION In the following detailed description of embodiments of the disclosure, numerous specific details are set forth in order to provide a more thorough understanding of the disclosure. However, it will be apparent to one of ordinary skill in the art that the disclosure may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description. Throughout the application, ordinal numbers (e.g., first, second, third, etc.) may be used as an adjective for an element (i.e., any noun in the application). The use of ordinal numbers is not to imply or create any particular ordering of the elements nor to limit any element to being only a single element unless expressly disclosed, such as using the terms “before”, “after”, “single”, and other such terminology. Rather, the use of ordinal numbers is to distinguish between the elements. By way of an example, a first element is distinct from a second element, and the first element may encompass more than one element and succeed (or precede) the second element in an ordering of elements. FIG.1shows a conventional cementing system in accordance with one or more embodiments. Specifically,FIG.1shows a wellbore (100) drilled into the Earths surface. The wellbore (100) traverses a lost circulation zone (102). A lost circulation zone (102) is a section of an underground formation where drilling fluid or cement (104) is lost to the formation. A lost circulation zone (102) may have partial lost circulation or total lost circulation. Partial lost circulation is when only some of the drilling fluid or cement (104) is lost to the formation. Total lost circulation is when all of the drilling fluid or cement (104) is lost to the formation. A lost circulation zone (102) may be a formation that is inherently fractured, cavernous, or has high permeability. A lost circulation zone (102) may also be a formation that has a lower fracture pressure than the surrounding formations. Thus, when this particular formation is being drilled with a mud heavier than the fracture pressure, or when the equivalent circulation density of the cement surpasses the fracture pressure, the formation is fractured and becomes a lost circulation zone (102). A casing string (106) has been run into the wellbore (100). The casing string (106) may be the only casing string (106) planned for the well, or the casing string (106) may be one of many casing strings (106) in the well/planned for the well without departing from the scope of this disclosure herein. The casing string (106) is made of a plurality of large diameter pipe threaded together. The casing string (106) may be made out of a material that can withstand downhole conditions, such as steel. The downhole portion of the casing string (106) may have a float shoe (108) and/or a float collar (not pictured). The float shoe (108) may include a one-way valve and a seat for one or more cement wiper plugs. The float shoe (108) may also have a rounded profile that aids in protecting the casing string (106) and running the casing string (106) to bottom. The casing string (106) has an inner circumferential surface (110) and an outer circumferential surface (112). The inner circumferential surface (110) defines a conduit (114). The inner circumferential surface (110) also defines the casing diameter (116). The space between the outer circumferential surface (112) and the wellbore (100) is the annulus (118). Cement (104) is pumped from a surface location (not pictured), downhole through the conduit (114) of the casing string (106), out of the float shoe (108), and up hole into the annulus (118). However, the cement (104) is unable to reach a pre-determined height in the annulus (118) due to the lost circulation zone (102). The cement (104) is only able to fill the annulus (118) up to the lost circulation zone (102), as the cement (104) reaches the lost circulation zone (102), the cement (104) is lost to the lost circulation zone (102). As such, a top job must be performed to fill the required space in the annulus (118) with cement (104). Conventional methods of performing a top job includes pumping cement (104) directly downhole through the annulus (118). This practice does not provide a way to properly displace the fluid, previously located in the annulus (118), with the cement (104). This contaminates the cement (104) and prevents the cement (104) from properly setting and bonding with the casing string (106) and the wellbore (100). Therefore, methods and systems that allow for cement (104) to be placed in an annulus (118) while circumventing the lost circulation zone (102) and displacing the fluid in the annulus (118) are beneficial. As such, embodiments presented herein describe methods and systems for a two-stage cement job that uses non-retrievable tubing to pump cement (104) into the annulus (118). FIGS.2aand2bshow a two-stage cement job in accordance with one or more embodiments. Components inFIGS.2aand2bthat are the same as or similar to components presented inFIG.1have not been redescribed for purposes of readability and have the same function and description as outlined above. Specifically,FIG.2ashows the system ofFIG.1undergoing the first stage of the cement job andFIG.2bshows the system ofFIG.1undergoing the second stage of the cement job. A cement basket (200) is connected to the outer circumferential surface (112) of the casing string (106). The cement basket (200) may be welded to or latched around the outer circumferential surface (112) of the casing string (106). Further, the cement basket (200) may be anchored to the outer circumferential surface (112) using one or more anchors (204). As shown inFIGS.2aand2b, the anchors (204) may be pieces of metal welded to the casing string (106) and the cement basket (200). In one or more embodiments, the anchors (204) may be formed in a tapered shape, that is, wider near the cement basket (200) and thinner near the casing string (106). In one or more embodiments, the anchor (204) may be a single metal ring welded between the cement basket (200) and the casing string (106). The anchors (204) are used to support the cement basket (200) from breaking down under the weight of the cement (104) slurry. In one or more embodiments, there may be a plurality of anchors (204), e.g., 4 to 6 anchors, connected to each cement basket (200). In one or more embodiments, a secondary cement basket may be nested within the first cement basket (200) to provide additional support. A cement basket (200) is an apparatus well known in the art that is configured to hold a slurry of cement (104). The cement basket (200) may be made out of overlapping metal fins that are flexible and form a bi-frustoconical shape. A fabric covering may be located within the cement basket (200) to cover the openings between the overlapping metal fins. The cement basket (200) is sized to bridge the space in the annulus (118). The cement basket (200) is installed at a location along the casing string (106) such that, when the entire casing string (106) is run in the wellbore (100), the cement basket (200) is disposed within the annulus (118) and located in proximity of and up hole from the lost circulation zone (102). Gravel (202) may be located within the cement basket (200). The gravel (202) may be placed in the cement basket (200) when the casing string (106) is at the surface. The individual rocks used in the gravel (202) may have different diameters to bridge the gaps between each rock. The gravel (202) prevents the cement slurry from passing through the cement basket (200) to the lost circulation zone (102). The first stage of the two-stage cement job is shown inFIG.2a. The first stage starts with performing a normal cement job as explained inFIG.1. Cement (104) is pumped from a surface location downhole through the conduit (114) of the casing string (106). The cement is pumped out of the float shoe (108) and up hole through the annulus (118). The cement (104) is pumped to the lost circulation zone (102) in the annulus (118). A wiper plug (206) may be pumped downhole through the conduit (114) of the annulus (118) to displace the cement (104) into the annulus (118) and wipe the inner circumferential surface (110) of cement (104). The wiper plug (206) may land in a seat in the float shoe (108) to conclude the first stage of the cement job. FIG.2bshows the planned top of cement (104) from the first stage.FIG.2balso shows the second stage of the cement job. A first tubing (208) is run into the annulus (118) between the outer circumferential surface (112) of the casing string (106) and the wellbore (100). A second tubing (210) may also be run into the annulus (118). The first tubing (208) and the second tubing (210) have a tubing diameter (214). The tubing diameter (214) is smaller than the casing diameter (116). The first tubing (208) and the second tubing (210) are made of a plurality of tubulars made out of s material that is able to withstand downhole conditions. The tubulars may be welded or threaded together to create the first tubing (208) and the second tubing (210). The first tubing (208) and the second tubing (210) may each have a one-way valve (212). The one-way valve (212) allows fluid to flow downhole through the first tubing (208) and the second tubing (210) and prevents fluid from flowing up hole through the first tubing (208) and the second tubing (210). The first tubing (208) and the second tubing (210) may each have a surface valve (not pictured) located on the surface-extending portion of the first tubing (208) and the second tubing (210). The surface valve allows and stops flow into the first tubing (208) and the second tubing (210). Cement lines (not pictured) may be connected to the first tubing (208) and the second tubing (210) using a union valve (not pictured). The first tubing (208) and the second tubing (210) are run into the annulus (118) to a depth proximate the cement basket (200). Cement (104) may be pumped into both the first tubing (208) and the second tubing (210), or cement may be pumped into only one tubing leaving the other as a backup. As shown inFIG.2b, the cement (104) is pumped downhole through the first tubing (208) and the second tubing (210). The cement (104) exits the first tubing (208) and the second tubing (210) into the annulus (118). The cement basket (200) and gravel (202) prevent the cement (104) from entering the lost circulation zone (102). The cement (104) is pumped up hole in the annulus (118) to the pre-determined height. In one or more embodiments, the cement (104) is pumped into the annulus (118) until clean cement (i.e., cement not contaminated with other fluids) is seen at the surface. Further, water or another fluid may be pumped into the first tubing (208) and the second tubing (210) to flush the tubing of cement (104). This allows the first tubing (208) and the second tubing (210) to be used in future remedial cementing operations. The first tubing (208) and the second tubing (210) are left in the annulus (118) as the cement (104) sets. FIGS.3aand3bshow a two-stage cement job in accordance with one or more embodiments. Components inFIGS.3aand3bthat are the same as or similar to components presented inFIGS.1-2bhave not been redescribed for purposes of readability and have the same function and description as outlined above. Specifically,FIG.3ashows the system ofFIG.1undergoing the first stage of the cement job andFIG.3bshows the system ofFIG.1undergoing the second stage of the cement job. As inFIGS.2aand2b, a cement basket (200) has been installed on the casing string (106) with at least one anchor (204). However, as the casing string (106) was run into the wellbore (100), the first tubing (208) and the second tubing (210) were connected to the casing string (106) and also run into the wellbore (100) at the same time. The first tubing (208) and the second tubing (210) may be connected to the casing string (106) by welding the first tubing (208) and the second tubing (210) to the outer circumferential surface (112) of the casing string (106) or by coupling the first tubing (208) and the second tubing (210) to the outer circumferential surface (112) of the casing string (106).FIG.3ashows the first stage of the two-stage cement job performed similar to the first stage performed inFIG.2a.FIG.3bshows the second stage of the two-stage cement job performed similar to the second stage performed inFIG.2b. FIG.4shows a flowchart in accordance with one or more embodiments. The flowchart outlines a method for cementing a wellbore (100) having a lost circulation zone (102). While the various blocks inFIG.4are presented and described sequentially, one of ordinary skill in the art will appreciate that some or all of the blocks may be executed in different orders, may be combined or omitted, and some or all of the blocks may be executed in parallel. Furthermore, the blocks may be performed actively or passively. Initially, a cement basket (200) is installed around a casing string (106) having a casing diameter (116) (S400). A secondary cement basket (200) may also be installed and nested within the first cement basket (200). At least one anchor (204) may be fastened to the cement basket (200) and the casing string (106) to support the cement basket (200). In one or more embodiments, 4-6 anchors are fastened to the cement basket (200) and the casing string (106). In other embodiments, more than two cement baskets (200) may be used in tandem to provide further support. Gravel (202) is located within the cement basket (200) to prevent cement (104) from migrating through the cement basket (200). The cement basket (200) may be filled with gravel (202) when the cement basket (200) is installed to the casing string (106) at the surface. The casing string (106) is run and set in the wellbore (100). The cement basket (200) is set in proximity of and up hole from the lost circulation zone (102) (S402). A cement (104) slurry is pumped, through the casing string (106), to a first depth downhole from the cement basket (200) (S404). The first depth may be located directly downhole from the lost circulation zone (102). A volume of cement may be pumped into or up hole from the lost circulation zone (102) without departing from the scope of the disclosure herein. A first tubing (208), having a tubing diameter (214), is run into an annulus (118) between the casing string (106) and the wellbore (100), wherein the tubing diameter (214) is less than the casing diameter (116) (S406). A second tubing (210), having the tubing diameter (214), may also be run into the annulus (118). The first tubing (208) and the second tubing (210) may be run into the annulus (118) after the casing string (106) has been run in the wellbore (100), or the first tubing (208) and the second tubing (210) may be connected to the casing string (106) as the casing string (106) is run into the wellbore (100). The first tubing (208) and the second tubing (210) may be connected to the casing string (106) by welding the first tubing (208) and the second tubing (210) to the casing string (106). The cement (104) slurry is pumped, through the first tubing (208), to a second depth up hole from the cement basket (200) (S408). The cement (104) slurry may also be pumped through the second tubing (210) to the second depth. In one or more embodiments, the second depth is at the surface. That is, the cement (104) is pumped into the annulus (118) until cement (104) is seen at the surface. Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. § 112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function. | 16,767 |
11859466 | Reference is initially made toFIG.1of the drawings which illustrates apparatus, generally indicated by reference numeral10, for creating axial movement of an inner sliding sleeve member12on a tool14in a downhole environment, according to an embodiment of the present invention. In this example, the tool14is a sub-surface safety valve which includes an inner sliding sleeve member12in the form of a flow tube whose axial movement opens and closes flapper16to operate the valve. In normal operation, hydraulic fluid is delivered from surface via a control line18, to act upon a piston20which forces the flow tube12downwards against a spring22, the flow tube12extending through the flapper16to hold it open. In this way, production fluids can pass up the bore24of the valve14to surface. If hydraulic fluid pressure is released on the control line18, the spring22forces the flow tube12upwards to uncover the flapper16, whereupon it will close the bore24and prevent the passage of fluids to surface. Re-applying pressure on the control line18will re-set the flapper16to the open position by moving the flow tube12back through the flapper16. This acts as a safety feature and accordingly, it is imperative that the flow tube12can move easily and does not become stuck in the valve14. At the upper end of the flow tube12there is a cylindrical section, which may be formed as a separate adaptor attached to the flow tube12. On this section there is provided a profile26. Profile26provides a change in the diameter of the bore24over an axial length of the bore24. The profile26typically is realised as a series of circumferential grooves. Apparatus10is best described with reference toFIGS.2(a)-(d). Centrally located through the apparatus10is an inner mandrel28being a substantially cylindrical body30. At a first upper end34there is arranged a top sub36having a connector38to attach the apparatus to a work string40directly or via other tools such as a jar42. At a lower second end44a bottom sub46is attached providing a bull nose48to direct the apparatus10through the bore24. On the upper side of the bottom sub46is an upward facing lip50at an outer edge. The lip50provides a circumferential ring with a chamfered edge spaced apart from the body30. Located around the inner mandrel28is a sleeve52. The sleeve52can rotate relatively around the inner mandrel28and travel axially along relatively to the inner mandrel28. The sleeve52includes a key carrier54. Key carrier54is an extension of the sleeve52and provides a recess56in which is located a number of keys58. In the example embodiment, there are six keys58equidistantly spaced around the carrier54in the recess56. Each key58has a part cylindrical body60, an inner surface62within which are located three cavities64, the outer surface68has a profile66machined therein, each profile66is identical being a series of grooves with straight and angled sides between upper and lower ends of the key58, with the ends angled down to provide an upper ledge70and a lower ledge72at each end of the key58. Upper and lower retaining rings74,76are located over the ledges70,72which may be keyed to prevent rotational movement of the keys58. In each cavity64is located a compression spring78, used to bias the key58away from a base of the recess56. Thus the keys are forced radially outwards from the apparatus10, with the radial travel restricted by the retainer rings74,76. However, the profile66on the outer surface68sits proud of the retainer rings74,76and the key carrier54when biased to their furthest position. The lower retainer ring76has an outer diameter less than the inner diameter of the lip50. In this way, the lip50can travel over the lower retainer ring76, contact the angled outer surface of the key58and, via its chamfered edge, push the key58back into the recess56against the springs78, to retract the outer surface68and the profile66into the key carrier54and apparatus10. The profile66is dimensioned to be the relief of the profile26on the tool14. In this way, the apparatus10can locate into and grip the inner sliding sleeve member12of the tool14, when run in the bore24and the profiles66,26are aligned to mate. The profiles66,26can be unique to ensure that the keys58of the apparatus10will not engage with any other profiles in the bore24when the apparatus10is run in. A further feature is an enlarged portion32on the inner mandrel28providing a greater diameter to the body30. This is best illustrated inFIG.2(c)showing the inner mandrel28with the outer surface42of the top sub36. The enlarged portion32includes a pocket80or recess at an upper end82. One pocket80is illustrated, but there may be others arranged around the enlarged portion32. The pocket80provides a base84being perpendicular to a central longitudinal axis86of the apparatus10. The base84may be considered as a stop102. Adjacent to the pocket80are slots88which are longitudinal grooves located entirely through the enlarged portion32. There may be any number of slots88around the enlarged portion32. A width of the pocket80is ideally equal to a width of the slot88. The sleeve52, as shown inFIG.2(d)has raised portions90upon its inner surface92. Although three lugs90are shown, there may be any number to align with the pockets32and slots88of the enlarged portion32of the inner mandrel28. The lugs90are located at a lower end94of the sleeve52and are dimensioned to fit with a pocket80and pass along a slot88. A further sleeve96is arranged and fastened to the inner mandrel28, towards its upper end34. This provides a first surface98facing the sleeve52, and as it is fixed to the inner mandrel28, provides a further stop100for relative longitudinal movement of the sleeve52. It is therefore apparent that the sleeve52including the key carrier54can move relative to the inner mandrel28between the stop100and the stop102when the lug90is aligned with the pocket80. When the lug is aligned with the slot88, sleeve52can bypass the enlarged portion32, travelling further and resulting in the upper lip50contacting the keys58. Further longitudinal movement will cause the keys58to retract into the recess56. It is the rotational alignment of the inner mandrel28and the sleeve52which will determine the extent of longitudinal movement allowed by the sleeve52relative to the inner mandrel28. In the embodiment shown, the rotational alignment is controlled by an indexing mechanism104. The first surface98of the further sleeve96is contoured106to describe a pathway with longitudinal sections108connected by angled sections110. An upper surface112on the sleeve52facing the first surface98has a mating contour114of longitudinal sections116and angled sections118. In this regard the sleeve52can be considered as a lower orientation sleeve52and the further sleeve is the upper orientation sleeve96. With the lower orientation sleeve52held in position via the keys58being radially extended against the inner sliding sleeve member12of the tool14, shifting the work string40will allow manipulation of the inner mandrel28so that it may be raised and shifted down to rotate the sleeves52,96relative to each other. This will align the lugs90with the pockets80or slots88. The positions can be cycled to operate the apparatus10. In use, the apparatus10is arranged with the lower orientation sleeve52between the upper orientation sleeve96and the bottom sub46. The apparatus10is mounted on a work string40and may include other tools, such as the jar42, as shown inFIG.1. The apparatus10is run-in the bore24of the tool14until the radially biased keys58engage in the profile26of the tool14. On run-in the apparatus10will be in a first configuration as illustrated inFIG.3(a). The upper and lower orientation sleeves52,96are adjacent with the contoured surfaces98,112mating and the surface98acting as a stop100preventing further movement of the lower orientation sleeve52upwards relative to the inner mandrel28. The lower orientation sleeve52is spaced apart above the enlarged portion32of the inner mandrel28. In this position, when the keys58engage and grip the inner sliding sleeve member12as the profiles26,66locate and mate, the apparatus10can be jarred downwards. A downward force is placed on the upper end34of the inner mandrel28, it is transmitted through the upper orientation sleeve96and by the contact of the surfaces98,112to the lower orientation sleeve52and the key carrier54. The downward force acts upon the keys58and consequently upon the inner sliding sleeve member12of the tool14. Such a jarring force should move the inner sliding sleeve member12axially downwards to exercise it or to release it if it has become stuck. The jarring down action can be repeated if further movement is required. Next the apparatus10is picked-up on the work string40. The upper and lower orientation sleeves96,52separate, moving down the longitudinal sections108,116of the contours106,114on surfaces98,112and the lugs90locate in the pockets80of the enlarge portion32. Travel of the sleeves52,96relative to each other is stopped as stop102is reached. The keys58remain engaged to the inner sliding sleeve member12and the apparatus10is then jarred upwards. The upward force placed on the upper end34of the inner mandrel28is transmitted to the lower orientation sleeve52through the pockets80of the enlarged portion32. The upward force acts upon the keys58and consequently upon the inner sliding sleeve member12of the tool14. Such a jarring force should move the inner sliding sleeve member12axially upwards to exercise it or to release it if it has become stuck. The jarring up action can be repeated if further movement is required. This second configuration of the apparatus is illustrated inFIG.3(b). The apparatus10is then shifted down with the upper orientation sleeve96meeting the lower orientation sleeve52and being directed along an angled section118of the surface112in the indexing mechanism104to rotationally align the lugs90with the slots88. This is as illustrated inFIG.3(c)with the upper and lower orientation sleeves96,52contacting each other again at the stop100. The apparatus10is then pulled on the work string40. When pulled, the keys58are initially retained in the profile26of the inner sliding sleeve member12, with the result that the inner mandrel28moves upwards relative to the fixed lower orientation sleeve52, and the slots88move over the lugs90, allowing the lower orientation sleeve52to bypass the enlarged portion32of the inner mandrel28. This upward movement of the inner mandrel28makes the upper lip50on the bottom sub46slide over the lower retaining ring76and contact the keys58. The chamfered edge of the lip50mates with the angled profile66and forces it radially inwards against the springs78as the lip50travels upwards relative to the keys58. The keys58are thus retracted into the recess56on the key carrier54. As the keys58are retracted, they have released from the profile26of the inner sliding sleeve member12and the upward pulling force on the apparatus10will raise the apparatus10in the bore and out of the tool14. This third configuration is shown inFIG.3(d). From the third configuration, the apparatus10can be run back into the profile26and by jarring down the index mechanism by be cycled to repeat the operation. This is useful if, once the apparatus10is outside the tool14, the inner sliding sleeve member12is found to still be stuck or not functioning correctly and the apparatus10can be re-used without having to be pulled to surface and redressed. As detailed above, with reference toFIG.1, the apparatus10can be used in a subsurface safety valve such as a tubing retrievable flapper valve which would be the tool14with a flow tube as the inner sliding sleeve member12. The apparatus10may therefore be considered as an exercise tool as is known in the art. For use as an exercise tool10in a tubing retrievable safety valve (TRSV)14, the exercise tool10is made up to a wireline tool string40comprising of a rope socket120, a six-foot stem122, mechanical jars42and the exercise tool10, as shown inFIG.1. The amount of stem122is used to adjust the tool string weight to ensure the wireline overcomes stuffing box friction to enter the well when the well is under pressure and determine the force applied in jarring down. Prior to running the tool string40, it should be determined if the flow tube12of the TRSV14is stuck in the open or closed position. This can be achieved by pressure determination in the well. It is important that if the TRSV14is closed, pressure must be equalized across the flapper16before attempting to manipulate the flow tube12with the exercise tool10. Severe damage to the flapper16or the hinge pin on which the flapper16pivots will occur if the jarring force of the exercise tool10on the flow tube12impacts the flapper16. The exercise tool10is run in hole until it reaches the TRSV14. Run in slowly until the keys58on the exercise tool10engage the mating exercise profile26in the top of the flow tube12. It will be necessary to jar up and down in order to determine the exercise tool position. For the scenario in that the flow tube12is stuck in the closed position i.e. TRSV14will not open hydraulically and the flow tube12will not move down under load from the hydraulic piston20. It is necessary to induce a downwards force from the exercise tool10to break the mechanical lock. Apply typical opening pressure to the TRSV control line18at surface and hold. Jar down lightly five times on the exercise tool10. Monitor the control line18pressure while jarring. If the pressure drops this indicates that the flow tube12and piston20are stroking down. Release the exercise tool10as described hereinbefore with reference toFIGS.3(a)-(d)and function the TRSV14by applying and bleeding off control line18pressure. Measure the volume of hydraulic fluid pumped into the valve14to determine if it is fully opening and closing. If the pressure is stable the flow tube12has not moved. Maintain the control line18pressure and repeat jarring action but with more force. Monitor control line18pressure for indications that the flow tube12is moving. If the pressure drops this indicates that the flow tube12and piston20are stroking down. Release the exercise tool10as described hereinbefore with reference toFIGS.3(a)-(d)and function the TRSV14by applying, and, bleeding off control line18pressure. Measure the volume of hydraulic fluid pumped into the valve14to determine if it is fully opening and closing. If after heavier jarring the flow tube12has still not moved increase the control line18pressure to the maximum allowable and repeat the step above. If the flow tube12has still has not moved it may be possible to spot acid within the valve bore24to remove scale or debris. If the mechanical lock cannot be removed by any means it may be necessary to run and install an insert valve within the TRSV14to allow the well to be produced safely. In the alternative where the flow tube12is stuck in the open position i.e. TRSV14will not close and the flow tube12will not move up under the power spring22force. It is necessary to induce an upwards force from the exercise tool10to break the mechanical lock. Ensure that no pressure is applied to the control line18and that it is vented to atmosphere. Jar up lightly five times on the exercise tool10. Measure the control line18returns while jarring. If the returned fluid matches the volume shown on the data sheet for the valve14this indicates that the flow tube12and piston20are stroking up. Release the exercise tool10as described hereinbefore with reference toFIGS.3(a)-(d)and function the TRSV14by applying and bleeding off control line18pressure. Measure the volume of hydraulic fluid pumped into the valve14to determine if it is fully opening and closing. If no returns are observed the flow tube12has not moved. Repeat jarring action but with more force. Monitor control line18returns for an indication that the flow tube12is moving. If the returned fluid matches the volume shown on the data sheet for the valve14this indicates that the flow tube12and piston20are stroking up. Release the exercise tool10as described hereinbefore with reference toFIGS.3(a)-(d)and function the TRSV14by applying, and, bleeding off control line18pressure. Measure the volume of hydraulic fluid pumped into the valve14to determine if it is fully opening and closing. If the flow tube12still has not moved after a number of attempts it may be possible to spot acid within the valve bore24to remove scale or debris. If the mechanical lock cannot be removed by any means it may be necessary to run and install an insert valve within the TRSV14to allow the well to be produced safely. The exercise tool10may also be used to lock the valve14open so that an insert valve can be installed. For this the exercise tool10is located on a wireline with mechanical jars42as described hereinbefore. Referring now toFIGS.4(a) to (c)there is shown a tubing retrievable safety valve14with a flow tube12. Like parts to the tool14ofFIG.1have the same reference numerals to aid clarity.FIG.4(a)illustrates the valve14in a closed configuration with the flapper16blocking the bore24whileFIG.4(b)illustrates the valve14in an open configuration with the flow tube12located through the flapper16to hold it open. The following method is used to decouple the flow tube12so that an insert valve can be installed. Pressurize up the tubing string24while recording the pumped volume to indicate when the pressure across the TRSV14is equalized and fluid is being pumped through the flapper valve16. Run in with exercise tool10to engage profile26on valve14with keys58on tool10and slack off tool string weight. Then pick-up tool string weight plus, say, 500 lb (227 kg) to indicate correct engagement in the profile26. Jar up strongly to shear release screws120in valve14. Jar down strongly to push flow tube12through flapper16far enough to allow profiled lip122on the outer surface124of the flow tube12to engage in profiled recess126on valve housing128to lock flow tube12in open position. Pump down control line18to verify that fluid is pumping into tubing string via TRSV bore24. Pick-up to disengage exercise tool10from profile26as described hereinbefore and POOH. The valve14is now as shown inFIG.4(c)and by replacing the exercise tool10with a wireline insert valve and running tool, the insert valve can be located in the TRSV14. The principle advantage of the present invention is that it provides apparatus and method for creating axial movement of an inner sliding sleeve member on a tool in a downhole environment which can release from and re-engage the inner sliding sleeve member while downhole. A further advantage of the present invention is that it provides an exercise tool for a sub-surface safety valve which is entirely mechanical with no seals or hydraulic control required, moves the safety valve flow tube up or down by jarring; releases from the safety valve as part of the jar up jar down operating sequence; doesn't require to be pooh and redressed if needed again once released and coupled with the relevant safety valve flow tube design the exercise tool can be used to lock open the safety valve so that an insert valve can be deployed. | 19,244 |
11859467 | The illustrated figures are only exemplary and are not intended to assert or imply any limitation with regard to the environment, architecture, design, or process in which different embodiments may be implemented. DETAILED DESCRIPTION In the following detailed description of the illustrative embodiments, reference is made to the accompanying drawings that form a part hereof. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is understood that other embodiments may be utilized and that logical structural, mechanical, electrical, and chemical changes may be made without departing from the spirit or scope of the invention. To avoid detail not necessary to enable those skilled in the art to practice the embodiments described herein, the description may omit certain information known to those skilled in the art. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the illustrative embodiments is defined only by the appended claims. The present disclosure relates to reservoir simulation systems and methods to dynamically improve performance of reservoir simulations. As referred to herein, a reservoir simulation system is a system formed from one or more electronic devices that individually or collectively perform operations described herein to generate one or more reservoir simulations. Examples of such electronic devices include, but are not limited to, desktop computers, laptop computers, server computers, tablet computers, smart phones, as well as other types of electronic devices operable to generate one or more reservoir simulations. Examples of reservoir simulations include, but are not limited to, simulations of hydrocarbon production of a reservoir over time, simulations of the amount of reservoir fluids (e.g., water) that flow into a wellbore over time, simulations of the cost of hydrocarbon production over time, simulations of the structure integrity of the reservoir over time, as well as other types of simulations of the reservoir. In some embodiments, a reservoir simulation includes a single simulation run of the respective simulation. In some embodiments, a reservoir simulation includes multiple simulation runs of the respective simulation. The reservoir simulation system includes a storage medium for storing data associated with simulations of a reservoir, such as, but not limited to, input variables for generating a reservoir simulation, output variables of the reservoir simulation, internal parameters that control the performance of the reservoir simulation, external parameters that control the performance of the reservoir simulation, historical data of previous simulation runs or simulations, as well as other types of data that are associated with simulations of the reservoir. As referred to herein, input variables are variables that are used to generate the reservoir simulation. Examples of input variables include, but are not limited to, fluid properties of a fluid flowing in a reservoir being simulated, properties of the reservoir being simulated, etc. In some embodiments, input variables are provided by the user. In some embodiments, input variables are predetermined or are selected from a recently generated reservoir simulation. Further, as referred to herein, output variables are one or more variables that are solved by the reservoir simulation. Examples of output variables include, but are not limited to, the amount of hydrocarbon resources produced (e.g., instantaneous output, output over time, etc.) by the reservoir being simulated, the amount of pressure at a location of the reservoir being simulated, the conductivity of the reservoir being simulated, etc. Further, as referred to herein, internal parameters are parameters and/or preconditions of one or more algorithms used to generate the reservoir simulation, whereas external parameters are parameters of one or more hardware components used to generate the reservoir simulation. Examples of external parameters include, but are not limited to, the number of processors, the number of simulation runs, etc. The reservoir monitoring system also includes one or more processors individually or collectively assigned to perform operations described herein, including obtaining input variables, internal parameters, and external parameters used in a reservoir simulation from the storage medium, generating a reservoir simulation based on the one or more input variables, determining a variance of the computation time for processing one or more processes of the reservoir simulation, and determining whether to perform a static optimization of the reservoir simulation or a dynamic optimization of the reservoir simulation based on the variance of the computation time for processing the one or more processes. Examples of methods for determining the variance of the computation time are provided in the paragraphs below. As referred to herein, a dynamic optimization of the reservoir simulation is a process to improve the reservoir simulation if the variance of the computation time is less than or equal to a threshold. The processors, in response to a determination that the variance of the computation time is less than or equal to the threshold, determine to perform a dynamic optimization of the reservoir simulation, and perform a first sequence of Bayesian Optimizations of one or more internal parameters and/or one or more external parameters of the reservoir simulation. Additional descriptions of a process for performing the first sequence of Bayesian Optimization are provided in the paragraphs below and are illustrated in at leastFIGS.1and2B. Further, as referred to herein, a static optimization of the reservoir simulation is a process to improve the reservoir simulation if the variance of the computation time is greater than the threshold value. In that regard, the processors, in response to determining that the variance of the computation time is greater than the threshold value, perform a second sequence of Bayesian Optimizations of one or more internal parameters and/or one or more external parameters of the reservoir simulation to improve performance of the reservoir simulation. Additional descriptions of a process for performing the second sequence of Bayesian Optimization are provided in the paragraphs below and are illustrated in at leastFIGS.1and2A. As referred to herein, a reservoir simulation is improved if the computing cost of performing the reservoir simulation is reduced, if the reservoir simulation is run more efficiently, and/or if the computation time is reduced. Examples of improving the reservoir simulation include, but are not limited to, reducing the computation time of the reservoir simulation to below a threshold period of computation time, reducing the cost of the reservoir simulation to under a threshold number of processors used to perform the reservoir simulation, reducing the energy utilization by one or more of the processors (e.g., mean energy consumption, variance in energy consumption, maximum energy consumption) to less than a threshold amount of energy consumption, reducing the computation time (e.g., variance in computation time, mean computation time, maximum computation time) of the processors to below a threshold amount of time, etc. In some embodiments, a reservoir simulation is improved by improving the values of the internal and external parameters that control the reservoir simulation. For example, where a value for an external parameter is number of processors, the computation time to perform the reservoir simulation can be changed by changing the number of processors, and the reservoir simulation is improved if the computation time to perform the reservoir simulation is reduced to a threshold time (e.g., under one minute, under 15 seconds, etc.) or is reduced by a threshold percentage (e.g., 10%, 15%, etc.) In some embodiments, the processors also obtain output variables of the reservoir simulation, the computation time of the reservoir simulation, and provide values of the output variables and the computation time for display. Additional descriptions of the foregoing systems and methods to dynamically improve performance of reservoir simulations are described in the paragraphs below and are illustrated inFIGS.1-3. Now turning to the figures,FIG.1is a flowchart of a process100to dynamically improve performance of a reservoir simulation. Although operations in the process100are shown in a particular sequence, certain operations may be performed in different sequences or at the same time where feasible. At block S102, one or more input variables for generating a reservoir simulation of a reservoir are obtained, where the reservoir simulation is associated with at least one of one or more internal parameters and one or more external parameters that control the performance of the reservoir simulation. In some embodiments, one or more of the internal and external parameters are provided by the user (e.g., a designation by the user to use no more than 10 processing units, a designation by the user to balance the load of the processors, a designation by the user to run a reservoir simulation for x number of times, etc.). In some embodiments, values of the one or more of the internal and external parameters are predetermined, or are based on values of a recently-run simulation. At block S104, a reservoir simulation is generated based on the one or more input variables. Examples of reservoir simulations include, but are not limited to, simulations of hydrocarbon production, simulations of the environment of the reservoir over time, as well as other types of simulations of the properties of the reservoir or the environment of the reservoir. As stated herein, in some embodiments, the reservoir simulation includes one or more simulation runs of the reservoir simulation over a period of time. At block S106, during the reservoir simulation, a variance of the computation time for processing the one or more processes of the reservoir simulation is determined. In some embodiments, the variance of computation time is a range of the computation times over a threshold number of time steps (e.g., 10, 15, 20, or another number of steps). For example, if the computation time over 10 time steps range from 5-15, then the variance over 10 time steps is 10. In some embodiments, the variance of computation time is the difference between a mean of the computation time over a first threshold number of time steps and a mean of the computation time over a second threshold number of time steps. For example, where the average computation time over the first threshold number of time steps (e.g., 10 time steps) is 10, and where the average computation time over the second threshold number of time steps (e.g., 10 steps) is 14, then variance of computation time is 4. In some embodiments, the variance of the computation time is an average of the squared differences from the mean computation time over a threshold number of time steps. At block S108, a determination of whether the variance is less than or equal to a threshold (e.g., 10, 5%, or another numerical value) is determined. In some embodiments, the threshold is a user-inputted value. In some embodiments, the threshold is a predetermined value. In some embodiments, the threshold is based on a threshold used in an earlier reservoir simulation. The process proceeds from block S108to S110if the variance is less than or equal to the threshold. At block S110, and in response to a determination that the variance of computation time is less than or equal to the threshold, a first sequence of Bayesian Optimizations of the at least one of the one or more internal parameters and the one or more external parameters is performed to improve performance of the reservoir simulation, such as, but not limited to, reducing the computation time of the reservoir simulation to below a threshold period of computation time, reducing the cost of the reservoir simulation to under a threshold number of processors used to perform the reservoir simulation, reducing the energy utilization by one or more of the processors (e.g., mean energy consumption, variance in energy consumption, maximum energy consumption) to less than a threshold amount of energy consumption, reducing the computation time (e.g., variance in computation time, mean computation time, maximum computation time) of the processors to below a threshold amount of time, etc. As described herein, a dynamic optimization of the reservoir simulation system is performed if the variance of the computation time is less than or equal to the threshold. Additional descriptions of the first sequence of Bayesian Optimizations are provided in the paragraphs below and are illustrated in at leastFIG.2B. The process then proceeds to block S114. Alternatively, the process proceeds from block S108to S112if the variance is greater than the threshold. At block S112, and in response to a determination that the variance of computation time is greater than the threshold, a second sequence of Bayesian Optimizations of the at least one of the one or more internal parameters and the one or more external parameters is performed to improve performance of the reservoir simulation. As described herein, a static optimization of the reservoir simulation system is performed if the variance of the computation time is greater than the threshold. Additional descriptions of the second sequence of Bayesian Optimizations are provided in the paragraphs below and are illustrated in at leastFIG.2A. The process then proceeds to block S114. In some embodiments, where the variance is less than or equal to the threshold, either the first sequence of Bayesian Optimizations or the second sequence of Bayesian Optimizations is performed. In one or more of such embodiments, and in response to a determination at block S108that the variance is less than or equal to the threshold, the user is prompted to select whether the user would like the first sequence of Bayesian Optimizations (proceed to block S110) or the second sequence of Bayesian Optimizations (proceed to block S112) to be performed. In one or more of such embodiments, and in response to a determination at block S108that the variance is less than or equal to the threshold, the processors dynamically determine whether to perform the first sequence of the Bayesian Optimizations or the second sequence of Bayesian Optimizations. In one or more of such embodiments, the processors determine whether to perform the first sequence of the Bayesian Optimizations or the second sequence of Bayesian Optimizations based on a previous user selection. In one or more of such embodiments, the processors determine the cost (e.g., computation time, energy consumption, number of processors, etc.) of performing the first sequence of Bayesian Optimizations and the second sequence of Bayesian Optimizations, and determines whether to perform the first sequence of the Bayesian Optimizations or the second sequence of Bayesian Optimizations based on the cost of performing the respective sequences of Bayesian Optimizations. At block S114, a determination of whether to perform another reservoir simulation is made. The process then returns to block S102in response to a determination to perform another reservoir simulation. Alternatively, the process ends if a determination not to perform another reservoir simulation is made. In some embodiments, one or more output variables (e.g., the amount of hydrocarbon resources produced (e.g., instantaneous output, output over time, etc.) by the reservoir being simulated, the amount of pressure at a location of the reservoir being simulated, the conductivity of the reservoir being simulated, etc.) of the reservoir simulation and the computation time of the reservoir simulation are also obtained and the values of the output variables and the computation time are provided for display (e.g., a display of an electronic device of the user). FIG.2Ais a flowchart of a process200to perform a static optimization of a reservoir simulation Although operations in the process200are shown in a particular sequence, certain operations may be performed in different sequences or at the same time where feasible. At block S202, one or more reservoir simulation runs of a reservoir simulation are run for a threshold number of iterations (e.g., 1 iteration, 10 iterations, or another integer number of iterations), each iteration lasting for a period of time (e.g., 1 millisecond, 1 second, duration of a threshold number of simulation runs, or another period of time). In some embodiments, the number of threshold iterations and the duration of the period of time per iteration are provided by the user. In some embodiments, the number of threshold iterations and the duration of the period of time are predetermined. In some embodiments, different iterations last different durations of time. At block S204, an objective function of the reservoir simulation is determined based on at least one of the one or more internal parameters and one or more external parameters. As referred to herein, an objective function (e.g. computation time) of the reservoir simulation is a function of the reservoir simulation and depends on the internal and external parameters, where one goal of the processes described herein is to determine values of one or more internal and/or external parameters at which objective function is optimum (e.g. minimum computation time, computation time is below a threshold value, minimum number of processors used, less than a threshold number of processors used, the variance of the number of computations performed by different processors is less than a threshold value, the energy consumption of the processors is less than a threshold amount of energy consumption, etc.). A few examples of objective function are, computation time, computation cost, energy consumption, etc. At block S206, a Bayesian Optimization of at least one of the one or more internal parameters and one or more external parameters are performed by utilizing calculated values for objective function to obtain new values for at least one of the internal parameters and the external parameters. In some embodiments, the Bayesian Optimization includes an acquisition function that suggests new values for the internal and external parameters based on previously-obtained values for objective function. At block S208, a determination of whether the reservoir simulation runs have been performed for a threshold number of iterations is made. The process returns to block S202if the reservoir simulation runs have not been performed for the threshold number of iterations, and the operations described in blocks S202, S204, and S206are performed again during and/or after a subsequent iteration, where one or more reservoir simulation runs in the next iteration are controlled by the new values of the internal parameters and/or external parameters obtained in the current iteration. In some embodiments, a Bayesian Optimization performed during the next iteration utilizes all previously-obtained values for objective function (at different values for internal and external parameters) to obtain new values for the internal and/or external parameters. The process described in blocks S202, S204, and S206, and S208are repeated for threshold number of iterations, and then values of the internal and external parameters are identified for which value of objective function is optimum (e.g. minimum computation time, computation time is below a threshold value, minimum number of processors used, less than a threshold number of processors used, the variance of the number of computations performed by different processors is less than a threshold value, or the energy consumption of the processors is less than a threshold amount of energy consumption, etc). These identified values for the internal and/or external parameters provide improved performance and are then utilized for reservoir simulation run. Alternatively, the process ends if the reservoir simulations have been performed for the threshold number of iterations. FIG.2Bis a flowchart of a process250to perform a dynamic optimization of a reservoir simulation. Although operations in the process250are shown in a particular sequence, certain operations may be performed in different sequences or at the same time where feasible. At block S252, one or more simulation runs of a reservoir simulation are generated for a period of time (e.g., 1 millisecond, 1 second, or another period of time). In some embodiments, the duration of the period of time is provided by the user. In some embodiments, the duration of the period of time is predetermined. At block S254, an objective function of the reservoir simulation is determined based on at least one of the one or more internal parameters one or more external parameters. At block S256, a Bayesian Optimization of at least one of the one or more internal parameters and one or more external parameters are performed to obtain new values for at least one of the internal parameters and the external parameters. At block S258, a determination of whether a threshold number of periods of time has elapsed is made. In some embodiments, the value of the threshold number of periods of time is inputted by the user. In some embodiments, the value of the threshold number of periods of time is predetermined. The process returns to block S252if the threshold number of periods of times has not elapsed, and the operations described in blocks S252, S254, and S256are performed again during and/or after the next period of time, where one or more reservoir simulation runs during the next period of time are controlled by the new values of the internal parameters and/or external parameters obtained in the current period of time. In some embodiments, a Bayesian Optimization performed during the next time period utilizes all previously-obtained values for the objective function (at different values for internal and external parameters) to obtain new values for the internal and/or external parameters. As the process described in blocks S252, S254, and S256, and S258are repeated, values of the internal and/or external parameters, that control the reservoir simulation and value of objective function are changed. After threshold number of periods of time have elapsed, values of the internal and/or external parameters are identified at which value of objective function is optimum (e.g. minimum computation time, computation time is below a threshold value, minimum number of processors used, less than a threshold number of processors used, the variance of the number of computations performed by different processors is less than a threshold value, or the energy consumption of the processors is less than a threshold amount of energy consumption, etc). These identified values for internal and/or external parameters are then utilized in reservoir simulation runs. Alternatively, the process ends if the threshold number of periods of times have elapsed. FIG.3is a block diagram of a reservoir simulation system300that is operable of performing operations illustrated in the processes ofFIGS.1,2A, and2Bto dynamically improve performances of a reservoir simulation system. Reservoir simulation system300includes a storage medium306and one or more processors310. Storage medium306may be formed from data storage components such as, but not limited to, read-only memory (ROM), random access memory (RAM), flash memory, magnetic hard drives, solid state hard drives, CD-ROM drives, DVD drives, floppy disk drives, as well as other types of data storage components and devices. In some embodiments, storage medium306includes multiple data storage devices. In further embodiments, the multiple data storage devices may be physically stored at different locations. Processors310represent one or more processors that individually or collectively perform operations described herein. In some embodiments, the one or more processors are components of a single electronic device, such as a desktop computer. In some embodiments, the one or more processors are components of different electronic devices that are located locally or remote from each other. In some embodiments, certain processes of the processors are assigned to perform certain operations (e.g., performing a first sequence of the Bayesian Optimizations), while other processors of the one or more processors are assigned to perform other operations (e.g., performing a second sequence of the Bayesian Optimizations). In some embodiments, different processors are assigned different operations to balance the workload among the processors. Data associated with simulations of a reservoir, such as, but not limited to, algorithms of simulations of the reservoir, user-inputted values (e.g., input variables, internal parameters, external parameters, number of iterations to run first and/or second sequences of Bayesian Optimizations, etc.), as well as predetermined values of variables and parameters described herein are stored at a first location320of storage medium306. In one or more embodiments, historical data of prior reservoir simulations are also stored at first location320of the storage medium306. As shown inFIG.3, instructions to obtain one or more input variables for generating a reservoir simulation of a reservoir are stored in a second location322. Further, instructions to generate the reservoir simulation based on the one or more input variables are stored in a third location324. Further, instructions to determine a variance of process time for processing one or more processes of the reservoir simulation are stored at a fourth location326. Further, instructions to perform a first sequence of Bayesian Optimizations of at least one of the one or more internal parameters and one or more external parameters to improve performance of the reservoir simulation are stored at a fifth location328. Further, instructions to perform a second sequence of Bayesian Optimizations of at least one of the one or more internal parameters and one or more external parameters to improve performance of the reservoir simulation are stored at sixth location330. Additional instructions that are performed by processor310are stored in other locations of the storage medium306. The above-disclosed embodiments have been presented for purposes of illustration and to enable one of ordinary skill in the art to practice the disclosure, but the disclosure is not intended to be exhaustive or limited to the forms disclosed. Many insubstantial modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the disclosure. For instance, although the flow charts depict a serial process, some of the steps/processes may be performed in parallel or out of sequence, or combined into a single step/process. The scope of the claims is intended to broadly cover the disclosed embodiments and any such modification. Further, the following clauses represent additional embodiments of the disclosure and should be considered within the scope of the disclosure: Clause 1, a method to dynamically improve performance of a reservoir simulation, the method comprising: obtaining one or more input variables for generating a reservoir simulation of a reservoir, the reservoir simulation comprising a plurality of reservoir simulation runs, and the reservoir simulation being associated with at least one of one or more internal parameters and one or more external parameters that control performance of the reservoir simulation; generating the reservoir simulation based on the one or more input variables; during the reservoir simulation, determining a variance of computation time for processing one or more processes of the reservoir simulation; in response to a determination that the variance of computation time is less than or equal to a threshold, performing a first sequence of Bayesian Optimizations of the at least one of the one or more internal parameters and the one or more external parameters to improve performance of the reservoir simulation; and in response to at least one of the determination that the variance of computation time is greater than the threshold, performing a second sequence of Bayesian Optimizations of the at least one of the one or more internal parameters and the one or more external parameters to improve performance of the reservoir simulation, wherein the one or more internal parameters are parameters of one or more algorithms used to generate the reservoir simulation, and wherein the one or more external parameters are parameters of one or more hardware components used to generate the reservoir simulation. Clause 2, the method of clause 1, wherein performing the first sequence of Bayesian Optimizations comprises: during each period of time of a threshold number of periods of time: generating one or more reservoir simulation runs of the reservoir simulation, wherein the one or more reservoir simulation runs are controlled by the at least one of the one or more internal parameters and the one or more external parameters; determining an objective function of the reservoir simulation based on the at least one of the one or more internal parameters and the one or more external parameters; and performing a Bayesian Optimization of the at least one of the one or more internal parameters and the one or more external parameters to obtain new values for the at least one of the one or more internal parameters and the one or more external parameters, wherein one or more reservoir simulation runs during a next period of time of the threshold number of periods of time are controlled by the new values for the at least one of the one or more internal parameters and the one or more external parameters. Clause 3, the method of clause 2, further comprising receiving a threshold value indicative of the threshold number of period of times, wherein the threshold value is a user-inputted value. Clause 4, the method of any of clauses 1-3, wherein performing the second sequence of Bayesian Optimizations comprises: for each iteration of a threshold number of iterations: generating one or more reservoir simulation runs of the reservoir simulation for a threshold period of time, wherein the one or more reservoir simulation runs are controlled by the one or more internal parameters and the one or more external parameters; determining an objective function of the reservoir simulation based on the at least one of the one or more internal parameters and the one or more external parameters; and performing a Bayesian Optimization of the at least one of the one or more internal parameters and the one or more external parameters to obtain new values for the at least one of the one or more internal parameters and the one or more external parameters, wherein one or more reservoir simulation runs in a next iteration of the threshold number of iterations are controlled by the new values for the at least one of the one or more internal parameters and the one or more external parameters. Clause 5, the method of any of clauses 1-4, wherein improving the performance of the reservoir simulation comprises reducing computation time of the reservoir simulation to below a threshold period of computation time. Clause 6, the method of any of clauses 1-5, wherein improving the performance of the reservoir simulation comprises reducing a cost of computing the reservoir simulation to under a threshold number of processors that perform the reservoir simulation. Clause 7, the method of any of clauses 1-6, wherein improving the performance of the reservoir simulation comprises reducing energy utilization by one or more processors that perform the reservoir simulation to below a threshold amount of energy consumption. Clause 8, the method of any of clauses 1-7, wherein improving the performance of the reservoir simulation comprises reducing a variance of computation time by different processors of one or more processors that perform the reservoir simulation to below a threshold amount of time. Clause 9, the method of any of clauses 1-8, further comprising after performing at least one of the first sequence of Bayesian Optimizations and the second sequence of Bayesian Optimizations, providing values of the one or more internal parameters and the one or more external parameters for display. Clause 10, the method of any of clauses 1-9, further comprising: obtaining one or more output variables of the reservoir simulation; obtaining a computation time of the reservoir simulation; and providing values of the one or more output variables and the computation time for display. Clause 11, the method of any of clauses 1-10, wherein in response to a determination that the variance of computation time is less than or equal to the threshold, performing one of the first sequence of Bayesian Optimizations of the at least one of the one or more internal parameters and the one or more external parameters or the second sequence of Bayesian Optimizations of the at least one of the one or more internal parameters and the one or more external parameters. Clause 12, a reservoir simulation system, comprising: a storage medium for storing data associated with simulations of a reservoir; and one or more processors operable to: obtain one or more input variables for generating a reservoir simulation of a reservoir, the reservoir simulation comprising a plurality of reservoir simulation runs, and the reservoir simulation being associated with at least one of one or more internal parameters and one or more external parameters that control performance of the reservoir simulation; generate the reservoir simulation based on the one or more input variables; during the reservoir simulation, determine a variance of computation time for processing one or more processes of the reservoir simulation; in response to a determination that the variance of computation time is less than or equal to a threshold, perform a first sequence of Bayesian Optimizations of the at least one of the one or more internal parameters and the one or more external parameters to improve performance of the reservoir simulation; and in response to at least one of the determination that the variance of computation time is greater than the threshold, perform a second sequence of Bayesian Optimizations of the at least one of the one or more internal parameters and the one or more external parameters to improve performance of the reservoir simulation, wherein the one or more internal parameters are parameters of one or more algorithms used to generate the reservoir simulation, and wherein the one or more external parameters are parameters of one or more hardware components used to generate the reservoir simulation. Clause 13, the reservoir simulation system of clause 12, wherein in response to a determination that the variance of computation time is greater than the threshold, the one or more processors are operable to: for each iteration of a threshold number of iterations: generate one or more reservoir simulation runs of the reservoir simulation for a threshold period of time, wherein the one or more reservoir simulation runs are controlled by the one or more internal parameters and the one or more external parameters; determine an objective function of the reservoir simulation based on the at least one of the one or more internal parameters and the one or more external parameters; and perform a Bayesian Optimization of the at least one of the one or more internal parameters and the one or more external parameters to obtain new values for the at least one of the one or more internal parameters and the one or more external parameters, wherein one or more reservoir simulation runs in a next iteration of the threshold number of iterations are controlled by the new values for the at least one of the one or more internal parameters and the one or more external parameters. Clause 14, the reservoir simulation system of clauses 12 or 13, wherein in response to a determination that the variance of computation time is less than or equal to the threshold, the one or more processors are operable to: during each period of time of a threshold number of periods of time: generate one or more reservoir simulation runs of the reservoir simulation, wherein the one or more reservoir simulation runs are controlled by the at least one of the one or more internal parameters and the one or more external parameters; determine an objective function of the reservoir simulation based on the at least one of the one or more internal parameters and the one or more external parameters; and perform a Bayesian Optimization of the at least one of the one or more internal parameters and the one or more external parameters to obtain new values for the at least one of the one or more internal parameters and the one or more external parameters, wherein one or more reservoir simulation runs during a next period of time of the threshold number of periods of time are controlled by the new values for the at least one of the one or more internal parameters and the one or more external parameters. Clause 15, the reservoir simulation system of any of clauses 12-14, wherein the one or more processors are operable to reduce computation time of the reservoir simulation to below a threshold period of computation time to improve the performance of the reservoir simulation. Clause 16, the reservoir simulation system of any of clauses 12-15, wherein the one or more processors are operable to reduce a cost of computing the reservoir simulation to under a threshold number of processes to improve the performance of the reservoir simulation. Clause 17, the reservoir simulation system of any of clauses 12-16, wherein the one or more processors are operable to reduce energy utilization by one or more processors that perform the reservoir simulation to below a threshold amount of energy consumption to improve the performance of the reservoir simulation. Clause 18, the reservoir simulation system of any of clauses 12-17, wherein the one or more processors are operable to reduce a variance of a number of computations performed by different processors of one or more processors that perform the reservoir simulation to below a threshold number of computations to improve the performance of the reservoir simulation. Clause 19, a machine-readable medium comprising instructions stored therein, which when executed by one or more processors, causes the one or more processors to perform operations comprising: obtaining one or more input variables for generating a reservoir simulation of a reservoir, the reservoir simulation comprising a plurality of reservoir simulation runs, and the reservoir simulation being associated with at least one of one or more internal parameters and one or more external parameters that control performance of the reservoir simulation; generating the reservoir simulation based on the one or more input variables; during the reservoir simulation, determining a variance of computation time for processing one or more processes of the reservoir simulation; in response to a determination that the variance of computation time is less than or equal to a threshold, during each period of time of a threshold number of periods of time: generating one or more reservoir simulation runs of the reservoir simulation, wherein the one or more reservoir simulation runs are controlled by the at least one of the one or more internal parameters and the one or more external parameters; determining an objective function of the reservoir simulation based on the at least one of the one or more internal parameters and the one or more external parameters; and performing a Bayesian Optimization of the at least one of the one or more internal parameters and the one or more external parameters to obtain new values for the at least one of the one or more internal parameters and the one or more external parameters, wherein one or more reservoir simulation runs during a next period of time of the threshold number of periods of time are controlled by the new values for the at least one of the one or more internal parameters and the one or more external parameters, and in response to a determination that the variance of computation time is 1 greater than the threshold, during each period of time of a threshold number of periods of time: for each iteration of a threshold number of iterations: generating one or more reservoir simulation runs of the reservoir simulation for a threshold period of time, wherein the one or more reservoir simulation runs are controlled by the one or more internal parameters and the one or more external parameters; determining an objective function of the reservoir simulation based on the at least one of the one or more internal parameters and the one or more external parameters; and performing a Bayesian Optimization of the at least one of the one or more internal parameters and the one or more external parameters to obtain new values for the at least one of the one or more internal parameters and the one or more external parameters, wherein one or more reservoir simulation runs in a next iteration of the threshold number of iterations are controlled by the new values for the at least one of the one or more internal parameters and the one or more external parameters. Clause 20, the machine-readable medium of clause 19, wherein the instructions, which when executed by one or more processors, causes the one or more processors to perform operations comprising: obtaining one or more output variables of the reservoir simulation; obtaining a computation time of the reservoir simulation; and providing values of the one or more output variable and the computation time for display. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprise” and/or “comprising,” when used in this specification and/or the claims, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. In addition, the steps and components described in the above embodiments and figures are merely illustrative and do not imply that any particular step or component is a requirement of a claimed embodiment. | 42,870 |
11859468 | BRIEF DESCRIPTION OF THE DRAWINGS The Rig State Estimation system, (“RSE”), may contain several parts including a model of rig state not as a single discrete “state” that can be entered and exited from, but as a collection of facts about a rig that may be estimated and updated in real-time. In addition to multiple sensors120, which may provide information such as measured surface readings or down-well measurements, RSE uses computer vision and machine learning algorithms specifically designed to estimate the rig state from video cameras102. The resulting information about rig state may then be incorporated into a display, along with other relevant pieces of information (e.g., video frames) and the state information is used to improve algorithm performance by altering the relative importance of the variables under consideration and other algorithm-level modifications. The information may also be used to form T&M databases112and reports, and to annotate the collected video with relevant T&M information. This would allow, for example, someone to immediately jump to all the instances of “roughneck engaged” or “adding barite to the pits” in a video feed. The information can help identify and flag uncommon events, presenting information about these events to the end-user in plain English. It may also be used to automate and generally improve rig behaviors. As a result total rig performance may be significantly enhanced. Classical estimates of rig “state” utilize a finite-set of discrete states corresponding to large-scale rig behavior, e.g., “Drilling”, “Pulling Out Of Hole”, “Out Of Hole”, “Running Into Hole”, etc. This is visualized inFIG.1. While these kinds of state models are useful when the number of states is small and can be easily described, in reality, the “state” of a rig is determined by dozens of interacting activities and behaviors. Complete enumeration of all of the possible combinations of activities and learning the probabilities of transitioning between all the states is typically intractable. Instead, this invention makes use of an alternative conceptualization of “state” which is shown inFIG.2. Here, each activity is represented as a column and time progresses from top to bottom. In this embodiment, each activity is represented as a binary variable (grouped binary variables are mutually exclusive, e.g., it is impossible to be drilling and pulling-out-of-hole simultaneously) which is updated at regular intervals (the intervals may be variable dependent, not shown).FIG.2shows a state evolution where the rig was initially drilling, then stopped to pull out of hole, and finally reached the state “out of hole.” Meanwhile, the volume in the pits was varied as the pits were emptied, and barite was added to the pits on and off during pulling out of the hole. Also, the iron roughneck was engaged and disengaged several times during the process (to disconnect pipe stands, for example). As shown in the embodiment ofFIG.2, the state may consist entirely of binary valued variables, but a state may also include discrete variables taking multiple possible values (e.g., the number of pipe-stands in the well), as well as real-valued states (e.g., hole depth). Estimating rig state as a number of discrete variables has a number of benefits over classical state estimation and tracking, for example, to account for all the various rig behaviors in a classical system requires an exponentially increasing number of discrete states, and an even larger number of inter-state transition probabilities. Depending on the state specification, different algorithms making use of different data sources are implemented to detect different relative variables. These algorithms use features from the relevant sensor data, together with machine learning algorithms for decision making. For example, to determine whether the rig is “pulling out of hole” an algorithm could utilize information from:1. the recent changes in bit depth and current hole depth,2. video of the pipe-stand, and pipe tracking outputs, and/or3. recent or ongoing roughneck engaged/disengaged measures. Information from each of these sensing modalities may be extracted using feature extraction approaches to generate low-dimensional, information bearing representations of the data. Low-level or quickly changing states that are likely to occur in a repeated sequence can be further aggregated into temporal models of likely behaviors within each larger state. For example, video observations of the rig floor during the “pulling out of hole” state are likely to iteratively determine three states in succession as depicted inFIG.3. Explicit small-scale state-transition models, like the one shown inFIG.3, are used to aggregate information temporally to improve evidence of the larger state inference (e.g., spending time in the activities shown inFIG.3adds credence to the “Pulling Out Of Hole” state). Throughout processing, each video camera102may incorporate human detection and tracking processing to identify the locations of people on the rig, flag any important occlusions (e.g., someone is blocking the camera's view of the drill hole), and/or record a person's motion and activities. These activities may then be utilized in automated T&M reporting. Information from the estimated rig state is also provided to systems for the identification of uncommon or dangerous state transitions and automated rig control systems (discussed below). Information about the global rig state may then be directly utilized in improving automated alarm generation systems. For example, information that there is barite added to the pits is used to change the influx detection system to ignore pit volume measurements for the time being. Similarly, information about the states “pipe static” and/or “pumps off” indicates that any positive change in flow-out and pit-volume may be highly indicative of down-well influx, since no other activities should be influencing those measurements. In addition to altering real-time processing and generally improving rig operations, computer vision based rig state detection and personnel tracking may also be used to automatically annotate video data as it is collected, along with the rig state, number of persons in scene, and other relevant sensor information. This processing may automatically add additional information to be attached to the video stream, to enable fast searching for discrete events (e.g., “show me every instance where tripping out of hole took more than 20 minutes but hole depth was less than 2000 ft”), which is currently intractable and extremely time-consuming with existing software. Embodiments of the system may show a prototype state visualization tool and sample frames from each “pipe-pulled” event found in the video. Each of these frames may provide a direct link to the corresponding point in the video. Each state-vector is recorded as a function of time and/or as part of a relational database (or other suitable software, e.g., a spreadsheet). These state-vector data sets are then used to automatically generate reports, and are made available to T&M analysts after data is collected. These data sets enable automatic searching over massive amounts of video that has been automatically tagged with T&M relevant information. For example, this enables identification of all events of type Y that took more than M minutes across all wells and rigs, using only already collected video and sensor data. This represents a large time savings and increase in the power and efficiency of T&M reporting. Each camera102may also keep track of all people in the scene using automated person-detection algorithms. When multiple cameras are viewing the same region, person locations can be estimated and provided as part of the automated T&M reporting and database—e.g., “Person 1 detected at location (x1,y1), Person 2 detected at location (x2,y2).” Persons may be automatically anonymized by blurring of the pixels containing detected persons for privacy and reporting reasons. Since the joint computer vision/down-well signal processing approaches described provides a state descriptor vector, which can be of very high dimension, estimating complete inter-state transition probabilities is intractable. However, by aggregating states into larger-picture states, or considering small sub-sets of states only (e.g., only the state descriptors shown in the left most group ofFIG.2) it is possible to accurately enumerate likely and dangerous transition probabilities by incorporating a priori expert information about realistic state transitions and state transitions that should be rare or impossible (e.g., a transition from “drilling” directly to “out of hole” most likely indicates a sensor failure or error, other transitions may indicate dangerous or environmentally unsafe behaviors or situations). Information from the computer vision and additional sensor state estimation techniques may also be used to determine appropriate rig control actions and automate rig behaviors and other processes through a supervisory control and data acquisition (“SCADA”) control system. FIG.4shows one embodiment of the disclosed system in which multiple cameras102may be used to monitor various aspects of the rig state. The cameras102are operably connected to a processor110. In this particular embodiment, the processor110is operably connected to a database112, alarm114, machinery control system116and sensor120. In related embodiments one, some or all of these devices may be operably connected to the processor110. Additionally, other embodiments may include, for example, multiple sensors120. FIG.5shows the steps of a method for estimating rig state. The disclosed method comprises the steps of sensing aspects of rig state302, collecting visual data,304, processing visual data to determine person location306, compiling multiple sources of rig data308, estimating rig state310, refining sensor data312, causing or inhibiting automated activities314, alerting staff316, annotating visual data318, recording data320and comparing compiled data against previously recorded data322. Other embodiments may include some or all of these steps in any sequence. Disclosed embodiments relate to a system for estimating global rig state. The system may include at least one camera102operably connected to at least one processor110, wherein the camera is capable of gathering visual data regarding at least one variable of rig state. The processor110is also capable of compiling rig state data, estimating global rig state, or both. The system may also include at least one sensor120for measuring at least one variable related to global rig state wherein the sensor120is operably connected to the processor110. The system may additionally include a model incorporating multiple variables related to rig state. In certain embodiments, the model variables can be updated in real time, the compiled data may be displayed to a user, and/or the estimated rig state may be used to refine data collected from said sensors. Some disclosed embodiments may also include a database112operably connected to the processor110, wherein the processor110is capable of comparing current data against historical data in the database. Additional embodiments may include an alarm system114for alerting staff to the occurrence of a pre-determined condition and/or a machinery control system116to cause or inhibit certain automated activities. In some embodiments, the visual data, sensor120measurements, estimated rig state or any combination thereof are searchable by the processor110. Some disclosed embodiments relate to a method for estimating rig state. The method may comprise the steps of sensing at least one aspects of the rig state302using at least one sensor120, collecting visual data304corresponding with the sensor data using at least one camera102, compiling multiple sources of rig data308and estimating the overall rig state310. In certain embodiments, the estimated overall rig state may be used to refine the gathered sensor data312and/or the determined person location may be used to cause or inhibit certain automated activities314. Some embodiments may also include the steps of processing visual data to determine person location306, alerting staff316to the occurrence of predetermined conditions, annotating gathered visual data318with corresponding rig state data, recording the compiled data320for future reference and/or comparing the compiled data against a database of previously recorded data322. | 12,594 |
11859469 | DETAILED DESCRIPTION This disclosure describes technologies relating to utilizing natural gas flaring byproducts for liquid unloading in gas wells. Natural gas flaring byproducts during flowback from a gas well can be used to perform post-stimulation liquid unloading and condensate unloading in the same gas well. Natural gas produced during the post-stimulation clean-up process before connecting the well to a production line is typically flared and released to the atmosphere. As described in this disclosure, the otherwise wasted flaring byproducts can be used by pumping the byproducts through a coiled tubing into a gas well to facilitate liquid unloading from the gas well. The flaring byproducts are therefore circulated through the gas well to unload liquids from the well. The subject matter described in this disclosure can be implemented in particular implementations, so as to realize one or more of the following advantages. The use of such flaring byproducts for this purpose can reduce the demand of nitrogen, which is typically used in liquid unloading processes. Further, the use of the flaring byproducts into a gas well to displace liquid from the same gas well can improve clean-up processes in preparation for hydrocarbon recovery. FIG.1depicts an example well100constructed in accordance with the concepts herein. The well100extends from the surface106through the Earth108to one more subterranean zones of interest110(one shown). The well100enables access to the subterranean zones of interest110to allow recovery (that is, production) of fluids to the surface106(represented by flow arrows inFIG.1) and, in some implementations, additionally or alternatively allows fluids to be placed in the Earth108. In some implementations, the subterranean zone110is a formation within the Earth108defining a reservoir, but in other instances, the zone110can be multiple formations or a portion of a formation. The subterranean zone can include, for example, a formation, a portion of a formation, or multiple formations in a hydrocarbon-bearing reservoir from which recovery operations can be practiced to recover trapped hydrocarbons. In some implementations, the subterranean zone includes an underground formation of naturally fractured or porous rock containing hydrocarbons (for example, oil, gas, or both). In some implementations, the well can intersect other types of formations, including reservoirs that are not naturally fractured. For simplicity's sake, the well100is shown as a vertical well, but in other instances, the well100can be a deviated well with a wellbore deviated from vertical (for example, horizontal or slanted), the well100can include multiple bores forming a multilateral well (that is, a well having multiple lateral wells branching off another well or wells), or both. In some implementations, the well100is a gas well that is used in producing hydrocarbon gas (such as natural gas) from the subterranean zones of interest110to the surface106. While termed a “gas well,” the well can produce dry gas and may incidentally, or in much smaller quantities, produce liquid including oil, water, or both. In some implementations, the production from the well100can be multiphase in any ratio. In some implementations, the production from the well100can produce mostly or entirely liquid at certain times and mostly or entirely gas at other times. For example, in certain types of wells it is common to produce water for a period of time to gain access to the gas in the subterranean zone. The concepts herein, though, are not limited in applicability to gas wells, oil wells, or even production wells, and could be used in wells for producing other gas or liquid resources or could be used in injection wells, disposal wells, or other types of wells used in placing fluids into the Earth. The wellbore of the well100is typically, although not necessarily, cylindrical. All or a portion of the wellbore is lined with a tubing, such as casing112. The casing112connects with a wellhead at the surface106and extends downhole into the wellbore. The casing112operates to isolate the bore of the well100, defined in the cased portion of the well100by the inner bore116of the casing112, from the surrounding Earth108. The casing112can be formed of a single continuous tubing or multiple lengths of tubing joined (for example, threadedly) end-to-end. InFIG.1, the casing112is perforated in the subterranean zone of interest110to allow fluid communication between the subterranean zone of interest110and the bore116of the casing112. In some implementations, the casing112is omitted or ceases in the region of the subterranean zone of interest110. This portion of the well100without casing is often referred to as “open hole.” The wellhead defines an attachment point for other equipment to be attached to the well100. For example,FIG.1shows well100being produced with a Christmas tree attached to the wellhead. The Christmas tree includes valves used to regulate flow into or out of the well100. In some implementations, the well100includes a combustion chamber203. The combustion chamber203can be used to combust a gas and is described in more detail later. FIG.2Ais a schematic diagram of a system200for liquid unloading in a well (for example, the well100). In some implementations, the well100has already been stimulated to promote hydrocarbon recovery from the well100. As natural gas is produced from the well100, liquids (for example, oil, condensate, and/or water) may accumulate over time. Liquids may accumulate due to a variety of factors, for example, a decrease in gas velocity in the well100, a decrease in reservoir pressure, a change in gas-to-liquid ratio, or a combination of these. The accumulated liquids can negatively impact production of natural gas from the well100. For example, as liquids accumulate in the well100, natural gas production from the well100may decline due to the increase in hydrostatic pressure in the well100. In some cases, liquid is used to stimulate the well100, and the liquid used to stimulate the well100needs to be unloaded from the well100. In some cases, the gas reservoir near the well100is saturated with stimulation liquid, and the liquid needs to be unloaded via the well100. A liquid unloading process can be implemented to unload the liquid and restore natural gas production from the well100. In some cases, gas (such as nitrogen) is pumped into the well100to facilitate the liquid unloading process. In this disclosure, during a liquid unloading process, natural gas produced from the well100is flared, and the flaring byproducts are pumped into the same well100to facilitate the liquid unloading process. In this way, the flaring byproducts are used instead of simply being wasted and released to the atmosphere. The use of the flaring byproducts can also reduce the use of nitrogen. A production stream201is produced from the well100. The production stream201includes a gaseous portion and a liquid portion. The gaseous portion can include, for example, natural gas. The liquid portion can include, for example, crude oil, gas condensate, an aqueous phase (that is, fluid including water), or a combination of these. The liquid portion has a base sediment and water (BS&W) percentage that can be measured, for example, at the surface106. In some implementations, phases of the production stream201(such as the gaseous portion and the liquid portion) are separated at the surface106. During the liquid unloading process, at least a portion of the gaseous portion of the production stream201is flowed to a combustion chamber203and combusted in the combustion chamber203. A source of oxygen (for example, air) can be flowed to the combustion chamber203to facilitate combustion of the gaseous portion of the production stream201. Combustion of the gaseous portion of the production stream201produces a flaring byproduct stream205. The flaring byproduct stream205can be made of mostly carbon dioxide (CO2). In some implementations, the flaring byproduct stream205is at least 99 volume percent (vol. %) CO2, at least 99.1 vol. % CO2, at least 99.2 vol. % CO2, at least 99.3 vol. % CO2, at least 99.4 vol. % CO2, at least 99.5 vol. % CO2, at least 99.6 vol. % CO2, or at least 99.7 vol. % CO2. CO2is a well-known greenhouse gas. Typically, flaring byproducts are simply released to the atmosphere and therefore contribute to overall emissions of a facility. Instead of releasing the flaring byproduct stream205to the atmosphere, some or all of the flaring byproduct stream205is flowed to the well100through a coiled tubing207. At least a portion of the flaring byproduct stream205can be flowed to the well100using, for example, a pump209. A tubing fluidically connects the combustion chamber203to the pump209, and at least a portion of the flaring byproduct stream205flows from the combustion chamber203to the pump209via the tubing. In some implementations, at least a portion of the flaring byproduct stream205is cooled before it is pumped into the well100. In some implementations, the system200includes a cooler211that cools the flaring byproduct stream205before it is pumped into the well100by pump209. The cooler211can be, for example, an air cooler or a shell-and-tube heat exchanger. The coiled tubing207is fluidically connected to the pump209. The pump209facilitates flow of the flaring byproduct stream205from the combustion chamber203and into the well100. Flowing the flaring byproduct stream205to the well100can facilitate liquid unloading from the well100. The production stream201continues to flow from the well100throughout the liquid unloading process. During the liquid unloading process, the BS&W percentage of the liquid portion of the production stream201can be measured, for example, using a sampler and/or a sensor. In some implementations, the system200includes a controller400that periodically communicates with the sampler and/or sensor to determine the BS&W percentage of the liquid portion of the production stream201. The controller400is described in more detail later. As the liquid unloading process progresses, the BS&W percentage of the liquid portion of the production stream201can decrease. The BS&W percentage can be correlated to an extent of liquid accumulation in the well100. Once the BS&W percentage has decreased enough to reach a threshold BS&W percentage, the liquid unloading process can be terminated. In some implementations, the threshold BS&W percentage is about 15%, about 10%, about 5%, about 4%, about 3%, about 2%, about 1%, or less than 1%. In some implementations, the flow rate and the pressure of the gas portion of the production stream201are measured. In cases where the production stream201is dry, once the flow rate of the gas portion of the production stream201has reached a threshold gas flow rate and/or the pressure of the gas portion of the production stream201has reached a threshold gas pressure, the liquid unloading process can be terminated. Termination of the liquid unloading process can include stopping combustion of the gaseous portion of the production stream201. Stopping combustion of the gaseous portion of the production stream201halts the production of the flaring byproduct stream205and therefore decreases the flow of the flaring byproduct stream205to the well100. Eventually, the flow of the flaring byproduct stream205to the well100stops. Termination of the liquid unloading process can include decreasing and/or stopping pumping of the flaring byproduct stream205by the pump209to the well100. In some implementations, the controller400is communicatively coupled to the pump209. In some implementations, the controller400is configured to transmit a stop signal to the pump209to decrease and/or stop pumping of the flaring byproduct stream205by the pump209to the well100in response to determining that the BS&W percentage measured by the sampler and/or sensor has reached the threshold BS&W percentage. In some implementations, the well100is connected to a gas processing plant after flow of the flaring byproduct stream205to the well100stops. Then the production stream201flows to the gas processing plant instead of being flowed to the combustion chamber203and back into the well100. In some implementations, the well100is connected to a gas pipeline (for example, for transport to a gas processing plant) after flow of the flaring byproduct stream205to the well100stops. Then the production stream201flows to the gas pipeline instead of being flowed to the combustion chamber203and back into the well100. FIG.2Bis a flow chart for a liquid unloading process250for a well (for example, the well100). The system200can implement the liquid unloading process250. As described previously, the well100is formed in a subterranean formation. In some implementations, the well100has been stimulated (for example, by using a stimulation liquid) before implementing the liquid unloading process250. At block252, a production stream (201) is received from the well100. As described previously, the production stream201includes a gaseous portion and a liquid portion. The liquid portion has a BS&W percentage that can be measured. At block254, at least a portion of gaseous portion of the production stream201is combusted to produce a flaring byproduct stream (205). At block256, the flaring byproduct stream205is flowed through a coiled tubing (207) to the well100. In some implementations, the flaring byproduct stream205is cooled before being flowed to the well100at block256. At block258, a BS&W percentage of the liquid portion of the production stream201is measured. At block260, the flow of the flaring byproduct stream205to the well100is decreased in response to the BS&W percentage reaching a threshold BS&W percentage. In some implementations, the threshold BS&W percentage is about 15%, about 10%, about 5%, about 4%, about 3%, about 2%, about 1%, or less than 1%. The flow of the flaring byproduct stream205to the well100can be decreased at block260by decreasing the amount of the gaseous portion of the production stream201that is combusted at block254. By decreasing the amount of the production stream201that is combusted, the amount of flaring byproducts produced is decreased. In some implementations, the flow of the flaring byproduct stream205to the well100is decreased at block260until the flow of the flaring byproduct stream205to the well100stops (that is, the flow rate of the flaring byproduct stream205reaches zero). In some implementations, the well100is connected to a gas processing plant after flow of the flaring byproduct stream205to the well100stops. Then the production stream201flows to the gas processing plant instead of being flowed to the combustion chamber203and back into the well100. In some implementations, the well100is connected to a gas pipeline (for example, for transport to a gas processing plant) after flow of the flaring byproduct stream205to the well100stops. Then the production stream201flows to the gas pipeline instead of being flowed to the combustion chamber203and back into the well100. FIG.3Ais a schematic diagram of a system300for liquid unloading in a well (for example, the well100). A production stream301is produced from the well100. In some implementations, the production stream301is substantially the same as the production stream201shown inFIG.2A. The production stream301includes a gaseous portion and a liquid portion. The gaseous portion can include, for example, natural gas. The liquid portion can include, for example, crude oil, gas condensate, an aqueous phase (that is, fluid including water), or a combination of these. The liquid portion has a base sediment and water (BS&W) percentage that can be measured, for example, at the surface106. In some implementations, phases of the production stream301(such as the gaseous portion and the liquid portion) are separated at the surface106. In some cases, pressure in the reservoir (also referred as reservoir pressure) is insufficient to meet a desired flow rate from the well100during the liquid unloading process. To promote flow of the production stream301from the well100, a nitrogen stream302is flowed to the well100through a coiled tubing307. The nitrogen stream302includes nitrogen (N2). In some implementations, the coiled tubing307is substantially the same as the coiled tubing207shown inFIG.2A. The nitrogen stream302can be flowed to the well100using, for example, a pump309. In some implementations, the pump309is substantially the same as the pump209shown inFIG.2A. During the liquid unloading process, at least a portion of the gaseous portion of the production stream301is flowed to a combustion chamber303and combusted in the combustion chamber303. In some implementations, the combustion chamber303is substantially the same as the combustion chamber203shown inFIG.2A. A source of oxygen (for example, air) can be flowed to the combustion chamber303to facilitate combustion of the gaseous portion of the production stream301. Combustion of the gaseous portion of the production stream301produces a flaring byproduct stream305. In some implementations, the flaring byproduct stream305is substantially the same as the flaring byproduct stream205shown inFIG.2A. The flaring byproduct stream305can be made of mostly CO2. In some implementations, the flaring byproduct stream305is about 99 vol. % CO2, at least 99 vol. % CO2, at least 99.1 vol. % CO2, at least 99.2 vol. % CO2, at least 99.3 vol. % CO2, at least 99.4 vol. % CO2, at least 99.5 vol. % CO2, at least 99.6 vol. % CO2, or at least 99.7 vol. % CO2. Instead of releasing the flaring byproduct stream305to the atmosphere, some or all of the flaring byproduct stream305is flowed to the well100through the coiled tubing307. At least a portion of the flaring byproduct stream305can be flowed with the nitrogen stream302to the well100through the coiled tubing307. A tubing fluidically connects the combustion chamber303to the pump309, and at least a portion of the flaring byproduct stream305flows from the combustion chamber303to the pump309via the tubing. At least a portion of the flaring byproduct stream305can be flowed to the well100using, for example, the pump309. In some implementations, at least a portion of the flaring byproduct stream305is cooled before it is pumped into the well100. In some implementations, the system300includes a cooler311that cools the flaring byproduct stream305before it is pumped into the well100by pump309. In some implementations, the cooler311is substantially the same as the cooler211shown inFIG.2A. The coiled tubing307is fluidically connected to the pump309. The pump309facilitates flow of the flaring byproduct stream305from the combustion chamber303and into the well100. Flowing the flaring byproduct stream305and the nitrogen stream302to the well100can facilitate liquid unloading from the well100. The production stream301continues to flow from the well100throughout the liquid unloading process. Because the flaring byproduct stream305is produced by combustion of the gaseous portion of the production stream301, the flow rate of the production stream301from the well100is directly related to the flow rate of the flaring byproduct stream305. The flow rate of the flaring byproduct stream305can be measured, for example, using a flowmeter. In some implementations, the controller400is communicatively coupled to the flowmeter and periodically communicates with the flowmeter to determine the flow rate of the flaring byproduct stream305. Once the flow rate of the flaring byproduct stream305reaches a threshold flow rate, the flow of the nitrogen stream302to the well100can be decreased. In some implementations, the controller400is communicatively coupled to a control valve that can be adjusted to control the flow rate of the nitrogen stream302. In some implementations, the controller400is configured to transmit a signal to the control valve to decrease and/or stop the flow of the nitrogen stream302to the pump309in response to determining that the flow rate of the flaring byproduct stream305has reached the threshold flow rate. In some implementations, the threshold flow rate is about 700 standard cubic feet per minute (SCFM). In some implementations, the flow rate of the nitrogen stream302is adjusted (for example, by the controller400), such that the total flow rate of the nitrogen stream302and the flaring byproduct stream305equals the threshold flow rate. As one example, at the beginning of the liquid unloading process, the nitrogen stream302is flowed at a flow rate equal to the threshold flow rate. As the production stream301flows from the well100and is combusted to produce the flaring byproduct stream305, the flaring byproduct stream305contributes to the overall flow along with the nitrogen stream302to the well100through the coiled tubing307. As the flow rate of the flaring byproduct stream305increases, the flow rate of the nitrogen stream302can be decreased, such that the total flow rate of the nitrogen stream302and the flaring byproduct stream305equals the threshold flow rate. Once the flow rate of the flaring byproduct stream305reaches the threshold flow rate, the flow of the nitrogen stream302to the well100can be terminated (that is, the flow rate of the nitrogen stream302reaches zero). The flow rate of the nitrogen stream302throughout these steps can be automatically controlled, for example, by the controller400. During the liquid unloading process, the BS&W percentage of the liquid portion of the production stream301can be measured, for example, using a sampler and/or a sensor. In some implementations, the system300includes a controller400that periodically communicates with the sampler and/or sensor to determine the BS&W percentage of the liquid portion of the production stream301. As the liquid unloading process progresses, the BS&W percentage of the liquid portion of the production stream301can decrease. Once the BS&W percentage has decreased enough to reach a threshold BS&W percentage, the liquid unloading process can be terminated. In some implementations, the threshold BS&W percentage is about 15%, about 10%, about 5%, about 4%, about 3%, about 2%, about 1%, or less than 1%. Termination of the liquid unloading process can include stopping combustion of the gaseous portion of the production stream301. Stopping combustion of the gaseous portion of the production stream301halts the production of the flaring byproduct stream305and therefore decreases the flow of the flaring byproduct stream305to the well100. Eventually, the flow of the flaring byproduct stream305to the well100stops. Termination of the liquid unloading process can include decreasing and/or stopping pumping of the flaring byproduct stream305by the pump309to the well100. In some implementations, the controller400is communicatively coupled to the pump309. In some implementations, the controller400is configured to transmit a stop signal to the pump309to decrease and/or stop pumping of the flaring byproduct stream305by the pump309to the well100in response to determining that the BS&W percentage measured by the sampler and/or sensor has reached the threshold BS&W percentage. In some implementations, the well100is connected to a gas processing plant after flow of the flaring byproduct stream305to the well100stops. Then the production stream301flows to the gas processing plant instead of being flowed to the combustion chamber303and back into the well100. In some implementations, the well100is connected to a gas pipeline (for example, for transport to a gas processing plant) after flow of the flaring byproduct stream305to the well100stops. Then the production stream301flows to the gas pipeline instead of being flowed to the combustion chamber303and back into the well100. FIG.3Bis a flow chart for a liquid unloading process350for a well (for example, the well100). The system300can implement the liquid unloading process350. As described previously, the well100is formed in a subterranean formation. In some implementations, the well100has been stimulated (for example, by using a stimulation liquid) before implementing the liquid unloading process350. At block352, a quantity of a nitrogen stream (302) is flowed through a coiled tubing (307) to the well100to begin the liquid unloading process350. At block354, a production stream (301) is received from the well100in response to flowing the nitrogen stream302at block352. At block356, at least a portion of the production stream301(for example, a gaseous portion of the production stream301) is combusted to produce a flaring byproduct stream (305). At block358, a quantity of the flaring byproduct stream305is flowed with the nitrogen stream302through the coiled tubing307to the well100to continue the liquid unloading process350. In some implementations, the flaring byproduct stream305is cooled before being flowed to the well100at block358. At block360, a flow rate of the flaring byproduct stream305is measured (for example, using a flowmeter). At block362, the flow of the nitrogen stream302to the well100is decreased in response to the flow rate of the flaring byproduct stream305reaching a threshold flow rate. In some implementations, the threshold flow rate is about 700 SCFM. In some implementations, the quantity by which the flow rate of the nitrogen stream302to the well100is decreased at block362is equal to an increase in the flow rate of the flaring byproduct stream305to the well100from block358to block362(for example, a difference between the threshold flow rate and an initial flow rate of the flaring byproduct stream305). In some implementations, the flow of the nitrogen stream302to the well100is decreased at block362until the flow of the nitrogen stream302to the well100stops (that is, the flow rate of the nitrogen stream302reaches zero). At block364, a BS&W percentage of the production stream301is measured. In some implementations, the BS&W percentage of the liquid portion of the production stream301is measured at block364. At block368, the flow of the flaring byproduct stream305to the well100is decreased in response to the BS&W percentage reaching a threshold BS&W percentage. In some implementations, the threshold BS&W percentage is about 15%, about 10%, about 5%, about 4%, about 3%, about 2%, about 1%, or less than 1%. The flow of the flaring byproduct stream305to the well100can be decreased at block368by decreasing the amount of the production stream301that is combusted. By decreasing the amount of the production stream301that is combusted, the amount of flaring byproducts produced is decreased. In some implementations, the flow of the flaring byproduct stream305to the well100is decreased at block368until the flow of the flaring byproduct stream305to the well100stops (that is, the flow rate of the flaring byproduct stream305reaches zero). In some implementations, the well100is connected to a gas processing plant after flow of the flaring byproduct stream305to the well100stops. Then the production stream301flows to the gas processing plant instead of being flowed to the combustion chamber303and back into the well100. In some implementations, the well100is connected to a gas pipeline (for example, for transport to a gas processing plant) after flow of the flaring byproduct stream305to the well100stops. Then the production stream301flows to the gas pipeline instead of being flowed to the combustion chamber303and back into the well100. FIG.4is a block diagram of an implementation of the controller400used to provide computational functionalities associated with described algorithms, methods, functions, processes, flows, and procedures, as described in this specification, according to an implementation. The illustrated computer402is intended to encompass any computing device such as a server, desktop computer, laptop/notebook computer, one or more processors within these devices, or any other processing device, including physical or virtual instances (or both) of the computing device. Additionally, the computer402can include a computer that includes an input device, such as a keypad, keyboard, touch screen, or other device that can accept user information, and an output device that conveys information associated with the operation of the computer402, including digital data, visual, audio information, or a combination of information. The computer402includes an interface404. Although illustrated as a single interface404inFIG.4, two or more interfaces404may be used according to particular needs, desires, or particular implementations of the computer402. Although not shown inFIG.4, the computer402can be communicably coupled with a network. The interface404is used by the computer402for communicating with other systems that are connected to the network in a distributed environment. Generally, the interface404comprises logic encoded in software or hardware (or a combination of software and hardware) and is operable to communicate with the network. More specifically, the interface404may comprise software supporting one or more communication protocols associated with communications such that the network or interface's hardware is operable to communicate physical signals within and outside of the illustrated computer402. The computer402includes a processor405. Although illustrated as a single processor405inFIG.4, two or more processors may be used according to particular needs, desires, or particular implementations of the computer402. Generally, the processor405executes instructions and manipulates data to perform the operations of the computer402and any algorithms, methods, functions, processes, flows, and procedures as described in this specification. The computer402can also include a database406that can hold data for the computer402or other components (or a combination of both) that can be connected to the network. Although illustrated as a single database406inFIG.4, two or more databases (of the same or combination of types) can be used according to particular needs, desires, or particular implementations of the computer402and the described functionality. While database406is illustrated as an integral component of the computer402, database406can be external to the computer402. The computer402also includes a memory407that can hold data for the computer402or other components (or a combination of both) that can be connected to the network. Although illustrated as a single memory407inFIG.4, two or more memories407(of the same or combination of types) can be used according to particular needs, desires, or particular implementations of the computer402and the described functionality. While memory407is illustrated as an integral component of the computer402, memory407can be external to the computer402. The memory407can be a transitory or non-transitory storage medium. The memory407stores computer-readable instructions executable by the processor405that, when executed, cause the processor405to perform operations, such as communicate with a sampler and/or a sensor to measure a flow rate of the production stream (201or301), communicate with a sampler and/or sensor to measure a flow rate of the flaring byproduct stream (205or305), communicate with a sampler and/or a sensor to measure a BS&W percentage of the production stream (201or301), any of the blocks of the process250, any of the blocks of the process350, or any combination of these. The computer402can also include a power supply414. The power supply414can include a rechargeable or non-rechargeable battery that can be configured to be either user- or non-user-replaceable. The power supply414can be hard-wired. There may be any number of computers402associated with, or external to, a computer system containing computer402, each computer402communicating over the network. Further, the term “client,” “user,” “operator,” and other appropriate terminology may be used interchangeably, as appropriate, without departing from this specification. Moreover, this specification contemplates that many users may use one computer402, or that one user may use multiple computers402. While this specification contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of features that may be specific to particular implementations. Certain features that are described in this specification in the context of separate implementations can also be implemented, in combination, in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations, separately, or in any sub-combination. Moreover, although previously described features may be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can, in some cases, be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination. As used in this disclosure, the terms “a,” “an,” or “the” are used to include one or more than one unless the context clearly dictates otherwise. The term “or” is used to refer to a nonexclusive “or” unless otherwise indicated. The statement “at least one of A and B” has the same meaning as “A, B, or A and B.” In addition, it is to be understood that the phraseology or terminology employed in this disclosure, and not otherwise defined, is for the purpose of description only and not of limitation. Any use of section headings is intended to aid reading of the document and is not to be interpreted as limiting; information that is relevant to a section heading may occur within or outside of that particular section. As used in this disclosure, the term “about” or “approximately” can allow for a degree of variability in a value or range, for example, within 10%, within 5%, or within 1% of a stated value or of a stated limit of a range. As used in this disclosure, the term “substantially” refers to a majority of, or mostly, as in at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more. Values expressed in a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a range of “0.1% to about 5%” or “0.1% to 5%” should be interpreted to include about 0.1% to about 5%, as well as the individual values (for example, 1%, 2%, 3%, and 4%) and the sub-ranges (for example, 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range. The statement “X to Y” has the same meaning as “about X to about Y,” unless indicated otherwise. Likewise, the statement “X, Y, or Z” has the same meaning as “about X, about Y, or about Z,” unless indicated otherwise. Particular implementations of the subject matter have been described. Other implementations, alterations, and permutations of the described implementations are within the scope of the following claims as will be apparent to those skilled in the art. While operations are depicted in the drawings or claims in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed (some operations may be considered optional), to achieve desirable results. In certain circumstances, multitasking or parallel processing (or a combination of multitasking and parallel processing) may be advantageous and performed as deemed appropriate. Moreover, the separation or integration of various system modules and components in the previously described implementations should not be understood as requiring such separation or integration in all implementations, and it should be understood that the described components and systems can generally be integrated together or packaged into multiple products. Accordingly, the previously described example implementations do not define or constrain the present disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of the present disclosure. | 36,483 |
11859470 | The diagrams depicted herein are illustrative. There can be many variations to the diagrams or the operations described therein without departing from the spirit of the invention. For instance, the actions can be performed in a differing order or actions can be added, deleted or modified. Also, the term “coupled” and variations thereof describes having a communications path between two elements and does not imply a direct connection between the elements with no intervening elements/connections between them. All of these variations are considered a part of the specification. DETAILED DESCRIPTION A detailed description of one or more embodiments of the disclosed system, apparatus, and method presented herein by way of exemplification and not limitation with reference to the figures. Disclosed are techniques for extracting hydrocarbons from a subterranean hydrocarbon reservoir based on an artificial lift plan. In some wellbore operations, fluids, such as crude oil and water, flow to the surface of the Earth without assistance due to the natural pressures within a reservoir. These are referred to as natural lift or natural flow reservoirs. However, many reservoirs do not have sufficient pressure to lift produced fluids to the surface of the Earth. Artificial lift increases the flow of these fluids in a wellbore operation to overcome insufficient pressures in the reservoir. Various artificial lift approaches can be implemented depending on wellbore operation properties, formation properties, reservoir properties, the life of the wellbore expectations, an amount of pressure needed to increase fluid flow, and other factors.FIG.1depicts examples of artificial lift approaches according to one or more embodiments described herein. In particular, examples of types of artificial lift approaches can include a gas lift system101, an electric submersible pump (ESP) system102, a progressing cavity pumping system103, a rod lift system104, a plunger lift system105, and the like. It should be appreciated that other systems/approaches can also be implemented, such as linear electric pumping systems, and/or combinations of these systems/approaches. One artificial lift approach may be better suited for a certain type of wellbore operation, for example, while not being as suitable for another type of wellbore operation. For example, an ESP-based approach may be better suited for deep wellbores producing thousands of barrels per day than a rod lift system. Frequently multiple artificial lift approaches may be suitable for a particular wellbore operation, and a decision must be made regarding which artificial lift approach to use. Selecting a non-ideal artificial lift approach can result in a reduced (non-ideal) production rate, lower (non-ideal) total production volumes (i.e., lower ultimate recovery), and the like, compared to an ideal artificial lift approach. Moreover, during the production lifetime of a reservoir, conditions may change; thus, what was once an ideal artificial lift approach can become non-ideal. Accordingly, it may be desirable to change artificial lift approaches over the life of a well. An example of an artificial lift plan is now described. In particular,FIG.2depicts an artificial lift plan200for a well according to one or more embodiments described herein. The artificial lift plan200shows production (in barrels of fluid per day (BFPD)) plotted over time (in months). As shown, three different artificial lift approaches are used depending on the life of the well. In the example ofFIG.2, a gas lift approach is implemented for the first approximately eleven months. After this period, an ESP-based approach is implemented until approximately twenty-four months (total lifetime of the well), at which point a rod lift approach is used. Existing techniques for developing an artificial lift plan rely on expertise and experience of individuals responsible for well production. Since experience and expertise vary significantly, reliance on individuals to address factors associated with production when developing artificial lift plans has led to considerable challenges due to bias and inconsistency. For instance, two similar wells use significantly different artificial lift plans depending on the experience and biases of the individuals who developed the artificial lift plans for the two wells. In an attempt to standardize the application of experience and reduce biases, prior techniques have attempted to apply rules based on captured knowledge from subject matter experts. However, these rules fail to consider, and are incapable of considering, changes to factors (dynamic factors) and lifetime-based factors. The technical solutions provide for developing an improved artificial lift plan over prior techniques by considering static factors, dynamic factors, and lifetime-based factors. Accordingly, the present techniques characterize changing conditions over the life of the well by identifying dynamic factors (i.e., factors that change over time), analyzing these dynamic factors along with static factors and lifetime-based factors, and developing an improved artificial lift plan that accounts for the static factors, dynamic factors, and lifetime-based factors. Consideration of dynamic factors and lifetime-based factors in combination with static factors allows a superior sequence of artificial lift configurations to be selected, thereby reducing likelihood of equipment failure, increasing system performance, enhancing production, increasing the viable life of a well, and increasing total ultimate recovery. The present techniques determine a total risk associated with operating various artificial lift approaches in a particular well under certain operating conditions. The total risk is calculated such that static factors known to influence artificial lift approaches (and the equipment associated therewith) efficacy or life are combined with dynamic factors that change over time. In this way, the impact of running equipment under non-ideal conditions, away from nominally rated design points, and for extended periods of time, can be accessed. A compromise can then be made between performance and technical risk, and a sequence of artificial lift approaches (i.e., an artificial lift plan) can be planned to achieve enhanced production and recover a greater portion of the available hydrocarbon resources in a reservoir. Static factors (also referred to as “static risk factors”) are factors that are associated with operating a particular lift configuration in a particular well and do not change over the period of operation. One example is the risk of premature tubing wear associated with running a rod-driven pump where the rods extend through a highly deviated wellbore. Another example is the risk of premature electric submersible pump failure when operated in a highly corrosive environment. Both of these examples of static factors are expected to apply over the entire life of the well and therefore are static. Dynamic factors (also referred to as “dynamic risk factors”) are factors associated with operating a particular lift configuration at a given operating condition and can change over the period of operation. One example is the risk of premature pump failure when running a rotating pump above its rated speed (such as running the pump at 150% of its rated speed). Another example is the risk of poor pumping performance that may include gas-lock when operating an ESP during a period of high gas production. Both of these factors can occur at specific intervals during the well production lifetime, and since the conditions driving these factors are expected to change over time, these factors are dynamic. Lifetime-based factors (also referred to as “lifetime-based risk factors”) are a function of the operating time for an artificial lift configuration. In other words, different types of artificial lift approaches are expected to have some maximum run lifetime, and the risk of failure increases as the operating time approaches the maximum run lifetime. Infant mortality may also be addressed as an increased risk level at the beginning of an operating interval for a pump that diminishes as time goes on. FIG.3depicts a block diagram of a processing system300for extracting hydrocarbons from a subterranean hydrocarbon reservoir based on an artificial lift plan according to one or more embodiments described herein. The processing system300includes a processing device302, a memory304, an evaluation engine310, a generation engine312, and a data store320. The components, modules, engines, etc. described regardingFIG.10can be implemented as instructions stored on a computer-readable storage medium, as hardware modules, as special-purpose hardware (e.g., application specific hardware, application specific integrated circuits (ASICs), application specific special processors (ASSPs), field programmable gate arrays (FPGAs), as embedded controllers, hardwired circuitry, etc.), or as some combination or combinations of these. According to aspects of the present disclosure, the engine(s) described herein can be a combination of hardware and programming. The programming can be processor executable instructions stored on a tangible memory, and the hardware can include the processing device302for executing those instructions. Thus a system memory (e.g., the memory304) can store program instructions that when executed by the processing device302implement the engines described herein. Other engines can also be utilized to include other features and functionality described in other examples herein. The functionality of the processing system300and its components are now described with reference toFIG.4. In particular,FIG.4depicts a flow diagram of a method400for extracting hydrocarbons from a subterranean hydrocarbon reservoir based on an artificial lift plan according to one or more embodiments described herein. The method400can be performed by any suitable processing system and/or processing device, such as the processing system300ofFIG.3and/or the processing system800ofFIG.9. At block402, the evaluation engine310performs a first evaluation of a first artificial lift approach that can be operated at a well having a subterranean hydrocarbon reservoir. The first evaluation is based at least in part on a first static factor and a first dynamic factor. The first static factor is a factor associated with operating the first artificial lift approach in the well and the first dynamic factor is a factor associated with operating the first artificial lift approach at a first operating condition. The static and dynamic factors can be stored in a data store, such as the data store320, and/or provided by a user, such as the user322. According to an example, the first artificial lift approach is a rod lift approach (e.g., using the rod lift system104ofFIG.1). In this case, an example of a static factor is that the rods extend through a highly deviated wellbore, and this can cause excess wear and tear on components of the rod lift system104. An example of a dynamic factor is that the rod driven pump of the rod lift system104may be at risk of premature pump failure when running at 150% of its rated speed. The evaluation engine310evaluates the static and dynamic factors of the rod lift approach to determine whether it should be implemented in a particular well and, if so, when and for how long. At block404, the evaluation engine310performs a second evaluation of a second artificial lift approach that can be operated at the well having the subterranean hydrocarbon reservoir. The second evaluation is based at least in part on a second static factor and a second dynamic factor. The first static factor is a factor associated with operating the second artificial lift approach in the well and the second dynamic factor is a factor associated with operating the second artificial lift approach at a second operating condition. According to an example, the second artificial lift approach is an ESP approach (e.g., using the ESP system102ofFIG.1). In this case, an example of a static factor is that the ESP can fail when operated in a highly corrosive environment. An example of a dynamic factor is gas-lock may occur when operating an ESP during a period of high gas production. The evaluation engine310evaluates the static and dynamic factors of the ESP approach to determine whether it should be implemented in a particular well and, if so, when and for how long. At block406, the generation engine312generates an artificial lift plan (e.g. the artificial lift plan200) based at least in part on the first evaluation and the second evaluation. The artificial lift plan indicates which artificial lift approach should be used at a particular well, when, and for how long. The artificial lift plan, which accounts for both static and dynamic factors, reduces likelihood of equipment failure, increases system performance, increases hydrocarbon recovery rate, increases the lifetime of a well, and increases total hydrocarbon recovery volume, according to embodiments described herein. The artificial lift plan defines which artificial lift approaches to use during certain operating periods, and further defines the operating period for which the approach is to be used. For example, an artificial lift plan can indicate to use an ESP approach for the first 12 months of a well's lifetime then switch to a rod lift approach for the next 13 months, etc. According to some examples, generating the artificial lift plan can be based on a risk level determined or calculated using the first static factor, the second static factor, the first dynamic factor, and/or the second dynamic factor. For example, each of the factors can have a value associated therewith (e.g., a value [0,1]), which indicates a risk probability index. The risk probability index is a statistical term indicating a measure of the likelihood and severity of an event such as equipment failure, where 0 indicates no likelihood of failure and 1 indicates the certainty of failure. This value may change over the life of the well, based on parameters associated with the well that affect static risk factors (e.g., corrosiveness of the wellbore environment, deviations from a straight-line in the trajectory of the wellbore, etc.), and/or changes to operating conditions that affect dynamic risk factors (e.g. reduced production rate that requires lower operating speed for a pump.) The risk level can be used to determine which artificial lift approach to use at what time and for how long. According to some examples, generating the artificial lift plan is based at least in part on an expected production value determined based on the first static factor, the second static factor, the first dynamic factor, and the second dynamic factor. The expected production value indicates the volume of hydrocarbons estimated to be recovered by each of the approaches, such as in volume per day. At block408, the hydrocarbons are extracted from the subterranean hydrocarbon reservoir based on the artificial lift plan by operating, at the well, at least one of the first artificial lift approach and the second artificial lift approach. For example, the hydrocarbons are extracted during a first period using a first artificial lift approach, then a second artificial lift approach is implemented to extract the hydrocarbons using the second artificial lift approach during a second period. Additional processes also may be included. For example, the generation engine312can generate a revised artificial lift plan based on changes to the dynamic factors (e.g., the first dynamic factor, the second dynamic factor, etc.), such as while the respective first and second artificial lift approaches are used. In some examples, the evaluations at blocks402and/or404can be calculated on lifetime-based factors. For example, in the case of an ESP approach, the estimated lifetime of an ESP can be considered in the evaluation, including infant mortality of the pump as an increased risk level at the beginning of an operating interval for a pump (e.g., the pump fails within the first week of implementation). It should be understood that the process depicted inFIG.4represents an illustration, and that other processes may be added or existing processes may be removed, modified, or rearranged without departing from the scope and spirit of the present disclosure. Comparisons between artificial lift approaches require an evaluation of the tradeoff between desirable (value) and undesirable (risk) quantities. It is therefore advantageous to provide insight to the risk level associated with a given artificial lift approach. In an embodiment,FIG.5Adepicts a line chart500overlaid on the cash flow area chart, which represents a risk level based on static factors. Similarly,FIG.5Bdepicts a line chart501overlaid on the cash flow area chart, which represents a risk level based on dynamic factors. As shown, the value is expected to change over time based on the variety of factors described above (e.g., static and/or dynamic factors). The magnitude of the risk level can be seen at any point during the analysis period from the charts500and501. While it is helpful to assess the static risk levels as shown in chart500, the exclusion of dynamic and life-based risk factors may fail to provide a thorough understanding of the risks associated with optionally implementing a particular plan. Contrarily, addressing static risk factors together with dynamic risk factors and life-based risk factors, as shown in chart501, provides information that could be vital to the overall risk associated with implementation of a particular plan. Regarding the chart501, two examples of penalty results are shown. Result502is an end range penalty result for an example of life-based penalty. In this example, gas lift Pinjectionis approaching a compressor max limit, and pump run time is approaching a maximum expected life. Result503is a bathtub range penalty result for an example of operating range (op-range) based penalty. In this example, an ESP run speed is near a minimum or maximum limit. Since the factors contributing to technical risk or suitability of the various artificial lift approaches are likely to vary between different operators, regions, and other qualifiers, it is useful to provide insights as to the source of risk. A construct to provide this insight is depicted inFIG.6. In particular,FIG.6depicts a screenshot of an expert advisor interface600according to one or more embodiments described herein. The expert advisor interface600can provide a summary list that shows the breakdown of risks factors that form the total risk level at any point within a lift plan timeframe. The risk elements include static, dynamic, and/or life-based factors associated with the selected timeframe. The expert advisor interface600can also list identified artificial lift types that failed certain logical tests that are considered within the plan. These logical tests may be referred to as “disallow rules” and viewing the triggered disallow rules for a plan indicates the reason why a particular artificial lift approach is excluded for consideration or is otherwise deemed inappropriate. FIG.7depicts a chart700to display risk elements at each point in time of operation of an artificial lift approach according to one or more embodiments described herein. Risk factors (static, dynamic, and lifetime-based) can be displayed to show the changing contribution of various risk elements to the total risk level over time. According to one or more embodiments described herein, a stacked bar chart is used to display the risk elements at each point in time for an artificial lift approach that is operational. From the example shown, it can be seen that several static risk elements persist from the beginning to the end of the artificial lift configuration operational period. It can also be seen that a dynamic risk element—“pump operating speed near maximum allowable”—contributes to increased risk at the beginning of the operational period. Finally, the life-based risk element—“pump runtime approaching expected end-of-life”—increase the risk level at the final operating points of the run period. It is understood that the present disclosure is capable of being implemented in conjunction with any other type of computing environment now known or later developed. For example,FIG.8depicts a block diagram of a processing system800for implementing the techniques described herein. In examples, processing system800has one or more central processing units (processors)821a,821b,821c, etc. (collectively or generically referred to as processor(s)821and/or as processing device(s)). In aspects of the present disclosure, each processor821can include a reduced instruction set computer (RISC) microprocessor. Processors821are coupled to system memory (e.g., random access memory (RAM)824) and various other components via a system bus833. Read only memory (ROM)822is coupled to system bus833and may include a basic input/output system (BIOS), which controls certain basic functions of processing system800. Further depicted are an input/output (I/O) adapter827and a network adapter826coupled to system bus833. I/O adapter827may be a small computer system interface (SCSI) adapter that communicates with a hard disk823and/or a tape storage drive825or any other similar component. I/O adapter827, hard disk823, and tape storage device825are collectively referred to herein as mass storage834. Operating system840for execution on processing system800may be stored in mass storage834. The network adapter826interconnects system bus833with an outside network836enabling processing system800to communicate with other such systems. A display (e.g., a display monitor)835is connected to system bus833by display adaptor832, which may include a graphics adapter to improve the performance of graphics intensive applications and a video controller. In one aspect of the present disclosure, adapters826,827, and/or232may be connected to one or more I/O busses that are connected to system bus833via an intermediate bus bridge (not shown). Suitable I/O buses for connecting peripheral devices such as hard disk controllers, network adapters, and graphics adapters typically include common protocols, such as the Peripheral Component Interconnect (PCI). Additional input/output devices are shown as connected to system bus833via user interface adapter828and display adapter832. A keyboard829, mouse830, and speaker831may be interconnected to system bus833via user interface adapter828, which may include, for example, a Super I/O chip integrating multiple device adapters into a single integrated circuit. In some aspects of the present disclosure, processing system800includes a graphics processing unit837. Graphics processing unit837is a specialized electronic circuit designed to manipulate and alter memory to accelerate the creation of images in a frame buffer intended for output to a display. In general, graphics processing unit837is very efficient at manipulating computer graphics and image processing, and has a highly parallel structure that makes it more effective than general-purpose CPUs for algorithms where processing of large blocks of data is done in parallel. Thus, as configured herein, processing system800includes processing capability in the form of processors821, storage capability including system memory (e.g., RAM824), and mass storage834, input means such as keyboard829and mouse830, and output capability including speaker831and display835. In some aspects of the present disclosure, a portion of system memory (e.g., RAM824) and mass storage834collectively store an operating system to coordinate the functions of the various components shown in processing system800. The teachings of the present disclosure may be used in a variety of well operations. These operations may involve using one or more treatment agents to treat a formation, the fluids resident in a formation, a wellbore, and/or equipment in the wellbore, such as production tubing. The treatment agents may be in the form of liquids, gases, solids, semi-solids, and mixtures thereof. Illustrative treatment agents include, but are not limited to, fracturing fluids, acids, steam, water, brine, anti-corrosion agents, cement, permeability modifiers, drilling muds, emulsifiers, demulsifiers, tracers, flow improvers etc. Illustrative well operations include, but are not limited to, hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, cementing, etc. Set forth below are some embodiments of the foregoing disclosure: Embodiment 1 A method includes: performing, by a processing device, an evaluation of an artificial lift approach that can be operated at a well having a subterranean hydrocarbon reservoir, the evaluation being based at least in part on a static factor associated with operating the artificial lift approach in the well and a dynamic factor associated with operating the artificial lift approach at a operating condition; generating, by the processing device, an artificial lift plan based at least in part on the evaluation; and extracting the hydrocarbons from the subterranean hydrocarbon reservoir based on the artificial lift plan by operating, at the well, the artificial lift approach. Embodiment 2 The method of any prior embodiment, the method further including generating, by the processing device, a revised artificial lift plan based at least in part on a change to the dynamic factor while extracting the hydrocarbons from the subterranean hydrocarbon reservoir. Embodiment 3 The method of any prior embodiment, wherein the artificial lift plan increases a hydrocarbon recovery rate, increases a lifetime of a well, and increases a hydrocarbon recovery volume. Embodiment 4 The method of any prior embodiment, wherein the evaluation is further based at least in part on a lifetime-based factor. Embodiment 5 The method of any prior embodiment, wherein generating the artificial lift plan is based at least in part on an expected risk value determined based on the static and the dynamic factor. Embodiment 6 A method includes performing, by a processing device, a first evaluation of a first artificial lift approach that can be operated at a well having a subterranean hydrocarbon reservoir, the first evaluation being based at least in part on a first static factor associated with operating the first artificial lift approach in the well and a first dynamic factor associated with operating the first artificial lift approach at a first operating condition; performing, by a processing device, a second evaluation of a second artificial lift approach that can be operated at the well having the subterranean hydrocarbon reservoir, the second evaluation being based at least in part on a second static factor associated with operating the second artificial lift approach in the well and a second dynamic factor associated with operating the second artificial lift approach at a second operating condition; generating, by the processing device, an artificial lift plan based at least in part on the first evaluation and the second evaluation; and extracting the hydrocarbons from the subterranean hydrocarbon reservoir based on the artificial lift plan by operating, at the well, at least one of the first artificial lift approach and the second artificial lift approach. Embodiment 7 The method of any prior embodiment, the method further including generating, by the processing device, a revised artificial lift plan based at least in part on a change to at least one of the first dynamic factor and the second dynamic factor while extracting the hydrocarbons from the subterranean hydrocarbon reservoir. Embodiment 8 The method of any prior embodiment, wherein the artificial lift plan increases a hydrocarbon recovery rate, increases a lifetime of a well, and increases a hydrocarbon recovery volume. Embodiment 9 The method of any prior embodiment, wherein the artificial lift plan defines a plurality of artificial lift approaches and an operational period associated with each of the plurality of artificial lift approaches. Embodiment 10 The method of any prior embodiment, wherein plurality of artificial lift approaches utilizes an artificial lift system selected from the group consisting of a gas lift system, an electric submersible pump (ESP) system, a progressing cavity pumping system, a rod lift system, and a plunger lift system. Embodiment 11 The method of any prior embodiment, wherein at least one of the first evaluation and the second evaluation is further based at least in part on a lifetime-based factor. Embodiment 12 The method of any prior embodiment, wherein the lifetime-based factor indicates an expected lifetime of a component of a system implementing the at least one of the first artificial lift approach and the second artificial lift approach. Embodiment 13 The method of any prior embodiment, wherein generating the artificial lift plan is based at least in part on an expected risk value determined based on the first static factor, the second static factor, the first dynamic factor, and the second dynamic factor. Embodiment 14 The method of any prior embodiment, wherein generating the artificial lift plan is based at least in part on an expected production value determined based on the first static factor, the second static factor, the first dynamic factor, and the second dynamic factor. Embodiment 15 A system is provided, system including a memory comprising computer readable instructions; and a processing device for executing the computer readable instructions for performing a method including: performing, by the processing device, a first evaluation of a first artificial lift approach that can be operated at a well having a subterranean hydrocarbon reservoir, the first evaluation being based at least in part on a first static factor associated with operating the first artificial lift approach in the well and a first dynamic factor associated with operating the first artificial lift approach at a first operating condition; performing, by a processing device, a second evaluation of a second artificial lift approach that can be operated at the well having the subterranean hydrocarbon reservoir, the second evaluation being based at least in part on a second static factor associated with operating the second artificial lift approach in the well and a second dynamic factor associated with operating the second artificial lift approach at a second operating condition; generating, by the processing device, an artificial lift plan based at least in part on the first evaluation and the second evaluation; and extracting the hydrocarbons from the subterranean hydrocarbon reservoir based on the artificial lift plan by operating, at the well, at least one of the first artificial lift approach and the second artificial lift approach. Embodiment 16 The system of any prior embodiment wherein the method further comprises generating, by the processing device, a revised artificial lift plan based at least in part on a change to at least one of the first dynamic factor and the second dynamic factor while extracting the hydrocarbons from the subterranean hydrocarbon reservoir. Embodiment 17 The system of any prior embodiment, wherein the artificial lift plan increases a hydrocarbon recovery rate, increases a lifetime of a well, and increases a hydrocarbon recovery volume. Embodiment 18 The system of any prior embodiment, wherein the artificial lift plan defines a plurality of artificial lift approaches and an operational period associated with each of the plurality of artificial lift approaches. Embodiment 19 The system of any prior embodiment, wherein plurality of artificial lift approaches utilizes an artificial lift system selected from the group consisting of a gas lift system, an electric submersible pump (ESP) system, a progressing cavity pumping system, a rod lift system, and a plunger lift system. Embodiment 20 The system of any prior embodiment, wherein the first evaluation is further based at least in part on a first lifetime-based factor, and wherein the second evaluation is further based at least in part on a second lifetime-based factor. Elements of the embodiments have been introduced with either the articles “a” or “an.” The articles are intended to mean that there are one or more of the elements. The terms “including” and “having” are intended to be inclusive such that there may be additional elements other than the elements listed. The conjunction “or” when used with a list of at least two terms is intended to mean any term or combination of terms. The term “coupled” relates to a first component being coupled to a second component either directly or indirectly via an intermediary component. The term “configured” relates to one or more structural limitations of a device that are required for the device to perform the function or operation for which the device is configured. The flow diagrams depicted herein are just examples. There may be many variations to these diagrams or the steps (or operations) described therein without departing from the spirit of the invention. For instance, the steps may be performed in a differing order, or steps may be added, deleted or modified. All of these variations are considered a part of the claimed invention. While one or more embodiments have been shown and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation. It will be recognized that the components or technologies may provide certain necessary or beneficial functionality or features. Accordingly, these functions and features as may be needed in support of the appended claims and variations thereof, are recognized as being inherently included as a part of the teachings herein and a part of the invention disclosed. While the invention has been described with reference to exemplary embodiments, it will be understood that changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications will be appreciated to adapt a particular instrument, situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. | 34,979 |
11859471 | DETAILED DESCRIPTION OF EXAMPLES OF THE INVENTION In the following description, certain terms have been used for brevity, clarity, and examples. No unnecessary limitations are to be implied therefrom and such terms are used for descriptive purposes only and are intended to be broadly construed. The different apparatus, systems and method steps described herein may be used alone or in combination with other apparatus, systems and method steps. It is to be expected that various equivalents, alternatives, and modifications are possible within the scope of the appended claims. Terms such as initiator are not to be construed as limiting. For instance, an initiator, which for example provides a high energy output for initiating a detonating cord, booster or other high explosive, in this description may also include an igniter or electric match, which provides flame and heat adapted for igniting a power charge, propellant, or similar pyrotechnic. Furthermore, initiator may include a stand alone heating element intended to initiate a high explosive or pyrotechnic device. A modular initiator is depicted inFIG.1AandFIG.1B. The modular initiator serves the purpose of providing a high energy output to initiate a second explosive device such as a detonating cord, a booster, a power charge, or propellant. The modular initiator requires electrical input to transfer electrical energy into a high energy output. The modular initiator contains a rigid connector for the purpose of assembling the initiator to a receiving circuit or installing in a contact block such that it may function as a standalone unit. The modular initiator may be used in a variety of explosive systems requiring electrical initiation. A contact block provides electrical feed through to allow the modular initiator to function without the need for additional electrical connections. The electrical circuit may be a printed circuit board, flexible circuit board, or other commonly used electrical boards or combinations. There may be many features included in the circuitry including switches, safety features, RF isolation, two-way communication with the surface, temperature measurement circuitry, pressure measurement circuitry, and other features not directly required for initiating the modular initiator. Electrical energy will pass through the electrical circuit to initiate the modular initiator through a rigid connector. Referring toFIGS.1A,1B, and1C, a modular initiator assembly10has a receptacle12having a latch16and contacts20are coupled to the connector13. Connector13includes contact blades19that engage with the contacts20. The contact blades19are further coupled to the resistors17aand17bvia resister leads18. Resister leads18, which may be continuous portions of contact blades19, are coupled to corresponding resistors17. A shell11is crimped onto the connector13. Wire14and15are coupled to the receptacle12. The design is such that each wire14or15has a corresponding contact20, a corresponding contact blade19, a corresponding resistor lead18, and a corresponding resistor17aor17b. Latch16locks the receptacle12into the connector13. Referring toFIGS.2A,2B,2C,2D,2E, and2F, a side cross section and corresponding side cross section of the modular initiator assembly10are shown in different stages of engagement. Stage 1 is depicted byFIGS.2A and2B. In stage 1 the receptacle12is partially inserted into the connector13, approximately one-third or less of the way inserted, there is no electrical connection between the receptacle12and connector13and the shunt, represented by shunt contacts22aand22b, are in the shunted position. In this configuration the modular initiator assembly10is self-protected from radio frequency signals and stray voltages. As can be seen inFIG.2B, the shunt contacts22aand22bare electrically in contact with each other, forming an electrical shunt between contact blades19aand19b. The latch16is not engaged. The signal contacts20aand20bare not engaged with the corresponding blades19aand19b. The separator21, a non-conductive wedge shaped part of the receptacle12, is not engaged with the shunt contacts22aand22b. Contact blades19aand19bhave corresponding resistor contacts18aand18b. The wires14and15can be arranged side by side, or opposite of each other, depending on the application. Stage 2 is depicted inFIGS.2C and2Dwhen the receptacle12is approximately between one third and two thirds of the way inserted into the connector13. Here electrical connections have been established between the receptacle12and the connector13while the shunt remains in place due to shunt contacts22aand22bstill being in contact. In this state the modular initiator assembly10is electrically protected by the initiator shunt and the circuit connected to the receptacle and is in a transition state. As can be seen inFIG.2D, the shunt contacts22aand22bare electrically in contact with each other, forming an electrical shunt between contact blades19aand19b. The latch16is deflected, but not engaged. The signal contacts20aand20bare engaged with the corresponding blades19aand19b. The separator21, is beginning to make contact with the shunt contacts22aand22b, but it has not yet separated them. Stage 3 is depicted inFIGS.2E and2Fwhen the receptacle12is more than two thirds of the way inserted into connector13. The receptacle12is in electrical communication with the connector13and is no longer shunted. As can be seen inFIG.2F, the shunt contacts22aand22bare not electrically in contact with each other due to separator21wedging them apart, therefore contact blades19aand19bare unshunted. The latch16is engaged into the connector13. The signal contacts20aand20bare engaged with the corresponding blades19aand19b. FIGS.3A and3Bshow additional detail of the connector13. The contact blades19aand19band their corresponding shunt contacts22aand22bare shown. Furthermore, contact blades19aand19bhave corresponding resistor contacts18aand18b. FIGS.4A and4Bshow additional detail of the receptacle12. The latch16is integrally formed to the receptacle. The wires14and15can be arranged side by side, or opposite of each other, depending on the application. InFIG.4Aone wire is strain-relieved while the other is not. InFIG.4Bboth wires are strain relieved. Referring toFIGS.5A,5B,5C,5D,5E, and5Fa side cross section and corresponding side cross section of the modular connector assembly200are shown in different stages of engagement. A modular initiator assembly200has a receptacle212having contacts220are coupled to the connector213. Connector213includes contact blades219that engage with the contacts220. The contact blades219are further coupled to the resistors217aand217bvia resister leads218. Stage 1 is depicted byFIGS.5A and5B. In stage 1 the receptacle212is partially inserted into the connector213, approximately one-third or less of the way inserted, there is no electrical connection between the receptacle212and connector213and the shunt, represented by shunt contacts222aand222b, are in the shunted position. In this configuration the modular initiator assembly210is self-protected from radio frequency signals and stray voltages. As can be seen inFIG.5B, the shunt contacts222aand222bare electrically in contact with each other, forming an electrical shunt between contact blades219aand219b. A latch may be used in this configuration to ensure a positive and locking engagement, but it is not shown. The signal contacts220aand220bare not engaged with the corresponding blades219aand219b. Therefore, the wires214and215are not connected. The separator221, a non-conductive part of the receptacle212, is not engaged with the shunt contacts222aand222b. Housing231is coupled to connector213. Stage 2 is depicted inFIGS.5C and5Dwhen the receptacle212is approximately between one third and two thirds of the way inserted into the connector213. Here electrical connections have been established between the receptacle212and the connector213while the shunt remains in place due to shunt contacts222aand222bstill being in contact. In this state the modular initiator assembly210is electrically protected by the initiator shunt and the circuit connected to the receptacle and is in a transition state. As can be seen inFIG.5D, the shunt contacts222aand222bare electrically in contact with each other, forming an electrical shunt between contact blades219aand219b. The signal contacts220aand220bare engaged with the corresponding blades219aand219b, however, because of the shunting, the signal contacts220aand220b, and their corresponding wires214and215, are connected. The separator221, is beginning to make contact with the shunt contacts222aand222b, but it has not yet separated them. Stage 3 is depicted inFIGS.5E and5Fwhen the receptacle212is more than two thirds of the way inserted into connector213. The receptacle212is in electrical communication with the connector213and is no longer shunted. As can be seen inFIG.5F, the shunt contacts222aand222bare not electrically in contact with each other due to separator221wedging them apart, therefore contact blades219aand219bare unshunted, and thus wires214and215are no longer in contact with each other. The signal contacts220aand220bare engaged with the corresponding blades219aand219b. Different configurations of a modular initiator assembly300are shown inFIGS.6A-6F. InFIGS.6A and6Bthe receptacle302is shown hard mounted to a circuit board301. The receptacle302connects to connector304. Connector304is coupled to an initiator303.FIG.6Ashows the receptacle302coupled to the connector304andFIG.6Bshows the receptacle302uncoupled from the connector304. InFIGS.6C and6Dthe receptacle302is shown attached to a circuit board301via wire leads305and306. The receptacle302connects to connector304. Connector304is coupled to an initiator303.FIG.6Cshows the receptacle302coupled to the connector304andFIG.6Dshows the receptacle302uncoupled from the connector304. InFIGS.6E and6Fthe receptacle302is shown with wire leads only. The receptacle302connects to connector304. Connector304is coupled to an initiator303.FIG.6Eshows the receptacle302coupled to the connector304andFIG.6Fshows the receptacle302uncoupled from the connector304. An example embodiment is shown inFIGS.7A,7B, and7Cwhere a modular initiator assembly400includes a circuit board401within a housing407. A receptacle402is hard mounted to the circuit board and protrudes from the housing407. The receptacle402is coupled to connector404. Connector404is coupled to initiator403. The distal end of a detonating cord408is held in placed by retainer409side-by-side to the initiator403. The detonating cord408may have a booster attached the distal end. An example embodiment is shown inFIGS.8A and8Bin a different configuration fromFIGS.7A,7B, and7C. The modular initiator assembly400includes a circuit board401within a housing407. A receptacle402is hard mounted to the circuit board and protrudes from the housing407. The receptacle402is coupled to connector404. Connector404is coupled to initiator403. The distal end of a detonating cord408is held in placed by retainer409side-by-side to the initiator403. The detonating cord408may have a booster attached to the distal end. An example embodiment is shown inFIG.9shows a jet cutter assembly500having a jet cutter top sub510coupled to a jet cutter housing512. Within jet cutter housing512is an initiator503located proximate to the jet cutter booster511for the jet cutter charge. The initiator503is coupled to the connector504. Connector504is coupled to the receptacle502. Receptacle502is hard mounted onto the circuit board housing501. An example embodiment is shown inFIG.10aof a perforating gun string assembly600. The gun string assembly600is suspended by a wireline640coupled to a cablehead assembly610. A fishing neck assembly611is coupled to and located downhole from the cablehead assembly610. A casing collar locator612is coupled to and located downhole from the fishing neck assembly611. A quick change assembly613is coupled to and located downhole from the casing collar locator612. A top sub601is coupled to and located downhole from the quick change assembly613. A first gun assembly602is coupled to and located downhole from the top sub601. The first gun assembly602contains a shaped charge606coupled to a detonating cord604. The detonating cord604is coupled to a modular initiator assembly605located within a switch tandem623. The switch tandem623is coupled to and located downhole from the first gun assembly602. The modular initiator assembly605is coupled to a bulkhead feedthrough608, which is further coupled to a feed thru puck assembly609that is held in place with a snap ring607. A second gun assembly622is coupled to and located downhole from the switch tandem623. A second switch tandem650is coupled to and located downhole from the second gun assembly622. Within the second switch tandem650is a modular initiator625that is further coupled to a bulkhead feedthrough628. A blast sleeve614is coupled to and located downhole from the second switch tandem650. A gun bottom615is coupled to and located downhole from the blast sleeve614. A close up cross section of switch tandem623is shown inFIG.10b. A modular initiator assembly605is located within bore634. A housing631containing a circuit board632is electrically coupled via a plurality of conductors to receptacle633. Receptacle633has been mated to connector635. Connector635has an initiator637coupled to it within a block636. A distal end630of detonating cord604is coupled to and a portion is located side-by-side the initiator637. An example embodiment of a t-shaped connector for a modular initiator700is shown inFIGS.11A and11B. A control fire board703within a housing704includes a t-shaped pin702connected to an initiator701. The pin705provides shunting and is removable. An example embodiment of a battery style modular initiator800is shown inFIGS.12A,12B,12C, and12D. An initiator801includes an explosive802, a wire807for initiating the explosive802, a first lead808that goes to a center point electrical contact804, an insulator805, a second lead803that contacts the electrically conductive exterior of initiator801. InFIG.12Bthe battery style modular initiator800is shown connected to a circuit board812with terminals810and811. InFIG.12Cthe battery style modular initiator800is located side-by-side detonating cord813. InFIG.12Dthe battery style modular initiator800has one set of contacts terminals810on the side of the initiator while the end contact terminal811is connected to the center point electrical contact. An example embodiment of a shunting initiator connection900with contact circuit is shown inFIGS.13A and13B. It has a detonator shell901, a short/shunt tab902, a shunt lift mechanism903, an electrical contact pin904, a connector housing905, and an electrical contact circuit906. There may be a plurality of pins904that are shunted by a single short/shunt tab902.FIG.13Ashows an example where the shunting initiator connection900is partially inserted andFIG.13Bshows an example where the shunting initiator connection900is fully inserted. An example embodiment of a self-shunting coaxial connector is shown inFIG.14. A coaxial male connector1000has an electrically conductive line1003, it may be coupled to a positive wire, and an outer electrically conductive spring contact1002, that may be coupled to a negative wire. The spring contact1002is by default in contact with line1003due to a springing action, which provides a self-shunting feature for the male connector1000. The female connector1001has an outer electrically conductive radial portion1004, a radial insulator1006, and an inner receptacle1005that is electrically conductive. Inner receptacle1005is coupled to a line1007. When the male connector1000is initially inserted into the female connector1000, the spring contact1002makes electrical contact with the radial portion1004and the line1003makes electrical contact with the receptacle1005. The curvature1008of the spring contact1002interfacing with the curvature1009of the female connector forces the spring contact1002away from the line1003as the male connector1000is fully inserted into the female connector1001, thus removing the shunt after first establishing electrical contact. The application for the example embodiments may be used with different types of initiators including resistor based bridgewire initiators, exploding bridge wire initiators, exploding foil initiators, and any other style of electric or electronic initiator. The modular initiator in the example embodiment is a packaged unit, which may include resistors, capacitors, or other electrical components. It may include a circuit board or other electronic circuitry. The modular initiator may be assembled or incorporated into an electrical circuit as a new assembly. The modular initiator may function as a standalone unit. A contact assembly without electronic circuitry may be employed which would receive the initiator and pass through electrical signals to the initiator. The modular initiator includes a shell containing a high explosive such as lead azide, RDX, HMX, HNS, a bridge element or foil initiator, and electrical components such as resistors, capacitors, spark gaps, electronic circuits, etc. The modular initiator may contain a rigid connector. The rigid connector may be incorporated in many configurations. The rigid connector may be a male pin-style or female style socket. The connector may incorporate a shunting mechanism. The purpose of the shunting mechanism is to act as a protective barrier against radio frequency (RF) energy and stray electrical energy by electrically shorting the contacts. The short length and removal of leg wires also creates RF resistance. The modular initiator must be protected from RF when transported off-site on public roads. The modular initiator could be installed to an electronic circuit with its own RF protection during the installation process. For situations where the shunt must be removed, a safety housing can be employed to protect personnel if the modular initiator were to initiate during installation. Robotics installation methods could also be used when shunting is not available. Auto-Shunting Electrical Connection or Auto-Shorting Electrical Connection (ASEC)—An ASEC is an electrical connection comprising at least one connector with a self-contained feature which electrically shorts two or more electrical contact paths of the connector when the connector is disconnected from, in the process of being disconnected from, or is being connected to a mating connector which includes at least one design feature which disengages the shorting feature of the first connector after electrical contact is established or allows the shorting feature of the first connector to reengage before electrical contact is broken. Auto-Shunting Electric Initiator or Auto-Shorting Electric Detonator (ASED)—An ASED is an electric or electronic initiator of any variety in which electrical energy is converted to an high energy output wherein the electric or electronic initiator includes the attached connector of an ASEC with the self-contained feature to electrically short two or more electrical contact paths and the electrical contact paths of the ASEC connector include the electrical contact paths of the electric or electronic initiator and at least part of the path through which electrical energy is converted to a high energy output. Initiators may be used to initiate a perforating gun, a cutter, a setting tool, or other downhole energetic device. For example, a cutter is used to cut tubulars with focused energy. A setting tool uses a pyrotechnic to develop gases to perform work in downhole tools. Any downhole device that uses an initiator may be adapted to use the modular initiator assembly disclosed herein. Although the invention has been described in terms of embodiments which are set forth in detail, it should be understood that this is by illustration only and that the invention is not necessarily limited thereto. For example, terms such as upper and lower or top and bottom can be substituted with uphole and downhole, respectfully. Top and bottom could be left and right, respectively. Uphole and downhole could be shown in figures as left and right, respectively, or top and bottom, respectively. Generally downhole tools initially enter the borehole in a vertical orientation, but since some boreholes end up horizontal, the orientation of the tool may change. In that case downhole, lower, or bottom is generally a component in the tool string that enters the borehole before a component referred to as uphole, upper, or top, relatively speaking. The first housing and second housing may be top housing and bottom housing, respectfully. In a gun string such as described herein, the first gun may be the uphole gun or the downhole gun, same for the second gun, and the uphole or downhole references can be swapped as they are merely used to describe the location relationship of the various components. Terms like wellbore, borehole, well, bore, oil well, and other alternatives may be used synonymously. Terms like tool string, tool, perforating gun string, gun string, or downhole tools, and other alternatives may be used synonymously. The alternative embodiments and operating techniques will become apparent to those of ordinary skill in the art in view of the present disclosure. Accordingly, modifications of the invention are contemplated which may be made without departing from the spirit of the claimed invention. | 21,600 |
11859472 | Like reference symbols in the various drawings indicate like elements. DETAILED DESCRIPTION An apparatus, system, and methods are disclosed for milling openings and closing openings in an uncemented blank pipe arranged in a horizontal well. The apparatus includes a milling sub-system for generating an opening in the blank pipe, and a plug sub-system for covering an opening generated by the milling system. The plug sub-system can also cover inflow control devices (ICDs) arranged in the blank pipe. The milling sub-system includes a bit (e.g., a drill bit) and braces that move the bit in contact with the blank pipe to generate the opening. The milling sub-system generates large, precise openings of a predetermined diameter, without compromising the integrity of the blank pipe. The milling sub-system forms openings in the blank pipe while reducing the risk of damage (e.g., cracking, splitting) to the blank pipe. In addition, the apparatus adjusts the number and size of the openings based on analysis and modeling of the formation, for example, the apparatus may mill openings near an area of the formation that is identified as a high-oil producing area and may close openings near areas of the formation that are identified as high-water producing areas. This configuration and methods increase the life of the well, increase the oil content of the recovered fluid, increase the amount of oil recoverable from the formation, and reduce the amount of ground water removed from the ground. The system operates riglessly and is cost effective by reducing downtime of the well. A high oil-producing area of the formation is identified by performing a multi-phase production log (PLT) and analyzing a produced water cut of the area of the formation. The produced water cut is the water produced rate divided by the total fluid produced rate and can be determined by a PLT or saturation log. Saturation logs can be taken at any time in the life of the well. A high oil-producing area is an area of the formation that has a produced water cut of 0% to 20% with an oil rate of about 1,000 barrels (bbl) per day (d). A 0% to 20% water cut is also known as “dry oil” or “low water” areas. In some cases, a high-oil producing area is identified by determining the oil production rate or by comparing the oil production rate of adjacent areas of the formation. A high water producing area is an area of the formation with a water cut of 50% or more. The estimated water cut in various areas of the formation is initially determined by analyzing wellbore data. Wellbore data can include horizontal multi-phase production logs, pressure data, and saturation data (generated by a saturation log), taken prior to oil recovery operations, for example prior to an inflow of oil or water from the formation, into the blank pipe. Wellbore data can also include fluid production data, for example, the water cut, formation permeability, reservoir pressure, relative permeability curves, productivity index, fluid PVT data, and formation skin damage as suggested by a pressure transient test. After estimating or calculating the water cuts of each area of the formation, the wellbore data is used to generate models that identify the portions of the blank pipe arranged in the high-oil producing areas, having a water cut of 0-20%, or high water-producing areas, having a water cut of 50% or greater. The models determine where to place additional openings to be milled by the apparatus. In some cases, the blank pipe may be arranged in a high oil-producing area but may not benefit from additional openings. For example, the openings may not be economically viable and/or may not increase the oil production enough to warrant intervention with the apparatus. The analysis of the model also determines the size of the openings. The size of the opening is determined by a processor to reduce any pressure drop across the blank pipe while maintaining the structural integrity of the blank pipe. Over the course of oil recovery, high-oil producing areas may transition into high-water producing areas as the oil in the high-oil producing areas is recovered and removed from the formation. During oil recovery the system can also analyze current wellbore data, measured during oil recovery, to detect, confirm, or re-categorize the high-oil producing areas and/or the high-water producing areas in real time. For example, the system may prompt or run additional saturation tests or PLT logs, analyze oil productions rates, water production rates, and/or the water cut. FIG.1is a view of an apparatus100for generating openings with a milling sub-system102. The apparatus100includes a housing104having a cylindrical wall106. The cylindrical wall106has an outer surface108on which the milling sub-system102is mounted. The housing104holds a processor110. The processor110is in communication with the milling sub-system102so that the processor110actuates the milling sub-system102. The milling sub-system102is mounted to an upper (first) side114of the wall106and is configured to mill an opening (not shown) in a blank pipe (not shown). The milling sub-system102includes a bit, for example a drill bit116, and a motor, for example a drill bit motor118. The drill bit116is configured to form the opening in the blank pipe by extending from the wall106and rotating, described in further detail with reference toFIGS.3A-3D. The milling sub-system102also includes braces120attached to a (bottom) second side121of the wall106. The braces120extend radially to move the drill bit116, with the housing104, towards the blank pipe. The braces120are arranged on the wall106at an opposite side from the drill bit116. The braces120are hinged arms connected to a motor. The arms rotate about a hinge to move from a retracted position to an extended (or partially extended) position, moving the drill bit116towards an inner surface of the blank pipe. The braces120are about 1 foot (ft) to 3 ft in length. Some housings have recesses that receive the braces during transport and alignment. Some braces are expandable arms. In use, the braces120, drill bit motor118, and the drill bit116generate an opening in an uncemented blank pipe by gradually applying pressure to the blank pipe via the drill bit116. This configuration and gradual application of force prevents the blank pipe from cracking and results in precise openings of a known size and location. The milling sub-system102also includes anchors122that extend around the outer surface108of the wall106. The anchors122are arranged helically around the outer surface108of the wall106. The anchors122releasably engage the inner surface of the blank pipe to temporarily mount the apparatus100to the blank pipe. The anchors122, when engaged, prevent downstream or upstream movement of the apparatus100, and by extension the drill bit116. The anchors122are extendable to the same length of the braces120such that, as the braces120extend to move the drill bit116towards the blank pipe, the anchors122also extend while maintaining the engagement between the blank pipe and the anchor122. In an extended or partially extended position, the braces120extend radially farther than the anchors122. In a retracted position, the anchors122extend radially farther than the braces120. In some systems, the braces120act as anchors during transport and act as braces during milling operations. The apparatus100includes an alignment sub-system123to align the apparatus100in the wellbore. The alignment sub-system includes a casing collar locator127. The casing collar locator127is configured to sense the depth of the apparatus and/or drill bit relative to the blank pipe. The casing collar locator127transmits the location and orientation of the apparatus100to the processor110, so that the processor110can confirm that the drill bit116is properly aligned with the intended location of an opening. Some alignment sub-systems include other sensors to confirm the location or orientation of the drill bit and to measure the condition of the blank pipe. In some systems, the apparatus includes a camera (not shown) for imaging the blank pipe to detect inflow control devices, openings, plugs, dads, or predetermined locations of the blank pipe. The camera is electronically connected with the processor. The apparatus100further includes a computer system111having the processor110and a computer-readable medium storing instructions executable by processor110to perform operations. The operations include analyzing wellbore data to estimate water cuts of each area of the formation. The wellbore data includes data generated or measured prior to oil recovery operations. Wellbore data can include data generated by a horizontal multi-phase production log and/or saturation logs. Production data includes data generated during oil recovery operations. The operations performed by the processor110also include determining high-oil producing areas of the formation that have an estimated water cut between 0% and 20% and/or high-water producing formations that have an estimated water cut of 50% or more. The computer system111is operable to control the alignment sub-system123, a plug sub-system (FIG.2), and the milling sub-system102. The computer system111prompts the alignment sub-system123to align the bit116of the apparatus100with the identified area of the blank pipe, and actuates the milling sub-system102to generate an opening in the blank pipe. The computer system111can also prompt the alignment sub-system123to align the plug sub-system (FIG.2) of the apparatus100with the identified high-water producing area, and actuate the plug sub-system (FIG.2) to cover an opening or inflow control device in the blank pipe. The apparatus100further includes a sensor arrangement125arranged on the housing104of the apparatus. The sensor arrangement is electronically connected to and controlled by the processor110. The sensor arrangement includes pressure sensors, fluid composition sensors, water cut sensors, pressure gauges, and tubing integrity sensors. The sensor arrangement125transmits sensor data to the processor110for analysis. The production data includes the sensor data transmitted by the sensor arrangement125. The sensor arrangement can include a pressure sensor on the drill bit for detecting the connection between the drill bit and the inner surface of the blank pipe. The sensor arrangement may also include a sensor that detects that an opening is completed. In some cases, the sensor arrangement also includes sensors that confirm the condition of the blank pipe prior to milling openings in the blank pipe. FIG.2is a view of a plug sub-system124and the extendable braces120of the milling sub-system102of the apparatus100. The plug sub-system124is configured to apply a plug, cover, or clad to cover the opening, inflow control device, or both the opening and the inflow control device. The plug sub-system124is clad sub-system that mounts a clad126to the inner face of the blank pipe. The plug sub-system124includes the dads126and a clad carrier128. The dads126are releasably held in or attached to the clad carrier128until the plug sub-system124is actuated by the processor110. The clad carrier128is attached to the wall106of the housing104. The clad126has a length of 5 ft to 10 ft and is made of metal. In some apparatuses, the plug sub-system includes a plug and a plug carrier mounted to the outer surface of the wall. In some cases, the plug sub-system includes mechanical saddles, bridge plugs, or expandable dads. In some systems, the plug sub-system is separate from the apparatus. The computer system is also operatively coupled to the plug sub-system. The computer system includes the processor110and a computer-readable medium storing instructions executable by the processor110to perform operations. The operations include identifying a portion of the blank pipe in a high-water producing area of a formation, aligning the plug sub-system124with the portion of the blank pipe, and actuating the plug sub-system124. FIG.3A-3Eare a cross sectional side views of a system150including the apparatus100in a horizontal well152of a formation154and an uncemented blank pipe156arranged in the well152. The system150is configured to generate openings in the uncemented blank pipe156and close openings in the uncemented blank pipe156using the apparatus100. The system150includes the blank pipe156arranged in the formation154. The formation154includes areas of high-oil saturation and areas of high-water saturation (low oil saturation). These areas can be estimated prior to oil recovery by performing wellbore modeling. FIG.3Ashows a cross-sectional view of the horizontal wellbore152and the blank pipe156of the system150. The blank pipe156includes inflow control devices (ICDs)158that extend through the blank pipe156. The inflow devices158fluidly connect the water and/or oil in the formation154to an interior volume160of the blank pipe156. The interior volume160is defined by an inner face of the blank pipe156. The ICDs158have a minimum pressure threshold that opens the ICD158, fluidly connecting the formation154to the interior volume160of the blank pipe156. The ICDs158act as a throttle for fluid (e.g., water or oil) flowing into the interior volume160of the blank pipe156at times, creating a pressure drop across the ICD158. The ICDs are uniform and produce similar inflow rates from portions of the blank pipe. The ICDs158are about 2 mm to 6 mm in diameter. The system150further includes multiple packers162, that have a first packer162a, a second packer162b, a third packer162c, and a fourth packer162d. The packers162are arranged circumferentially around the blank pipe156in an annulus space166defined between the formation154and the blank pipe156. The packers162divide the blank pipe156into portions168of the blank pipe156. The portions168include a first portion168athat is defined from the beginning of the horizontal wellbore152to the first packer162a, a second portion168bthat is defined from the first packer162ato the second packer162b, a third portion168cthat is defined from the second packer162bto the third packer162c, a fourth portion168dthat is defined from the third packer162cto the fourth packer, and a fifth portion168ethat is defined from the fourth packer162dto an end face170of the well152. In use, the apparatus100moves in the interior volume160of the blank pipe156to access different portions168of the blank pipe156. Each of the portions168of the blank pipe156align with corresponding areas of the formation154. The areas of the formation154may be high-oil producing areas or high-water producing areas. In some cases, the high-oil producing areas are depleted over time and transition into high-water producing areas. FIG.3Bshows a cross sectional side view of the system150as the apparatus100aligns with a portion168of the blank pipe156that corresponds to a high-oil producing area of the formation154. The apparatus100is translated along the blank pipe156by a wireline174or an active coil. The high-oil producing area of the formation154and the associated portion168of the blank pipe is identified by well modelling. Wellbore modeling is constructed to design the job, number and size of the ports (opening), and forecast the water cut and/or production rates to run economics of the job design. The well model can be based on wellbore data that includes water cut estimations, productivity tests, productivity logs, recent production data, recent pressure data, current production data, current pressure data, recent horizontal multi-phase logs, water entries, PVT fluid data, relative permeability curves, and oil entries. In the system150, the second portion168band fourth portion168dof the blank pipe156correspond to high-oil producing areas of the formation154. The apparatus100is aligned with the second portion168bof the blank pipe156and the processor110actuates the milling sub-system102. Prior to actuating the milling sub-system102, the processor defines a predetermined diameter of the opening. FIG.3Cshows the actuated milling sub-system102. The milling sub-system102generates an opening178in the second portion168bof the blank pipe156. The braces120move from the retracted position to the extended position by rotating about a hinge. This movement, presses the apparatus100towards the inner face of the blank pipe156until the drill bit116abuts the inner face of the blank pipe156. The drill bit116rotates by the drill motor118and begins to mill the opening178into the blank pipe156. The braces120continue to rotate about the hinge and the drill bit116continues to apply pressure to the blank pipe156until the opening178is defined in the blank pipe156and has the predetermined diameter. The openings178are larger than the ICDs158(e.g., about 10 to 50 times larger than the ICD). The diameter of the openings178can be between 5 mm and 300 mm (e.g., 10 mm to 30 mm). After the opening178is formed, the milling sub-system102is deactivated by the processor110. The braces120move into the retracted position and the apparatus100is lowered away from the inner face of the blank pipe156. The apparatus100is free to move uphole or downhole to align the apparatus100with a different portion168of the blank pipe156. In the system150, the apparatus100moves downhole to align with the fourth portion168dof the blank pipe156that also corresponds to o a high-oil producing area of the formation154. FIG.3Dshows the actuated milling sub-system102drilling an opening180in the fourth portion168dof the blank pipe156. The processor110actuates the milling sub-system102and the braces120move into the extended position to apply pressure to the inner face of the blank pipe156via the drill bit116. FIG.3Dshows the plug sub-system124after applying a clad126to the second portion168bof the blank pipe156. In the system150, the second portion168bwas in a high-oil producing area of the formation154. As the oil moved from the formation154to the interior volume160of the blank pipe156, the high-oil producing area transitioned into a high-water producing area. The system150detects this transition from high-oil producing to high-water producing and, in response, closes or covers the opening178and ICD158in the second portion168b. High-water producing areas are detected by the well model and later by analyzing wellbore (production) data generated during the oil production operation. The production data can include water cut estimations or measurements, productivity tests, productivity logs, recent production data, recent pressure data, current production data, current pressure data, recent horizontal multi-phase logs, water entries, and oil entries. The system may include a multi-phase flow meter (MPFM) installed in the surface to periodically measure well production performance. The MFPM may be connected to the processor of the apparatus or a computer system at the surface connected to the processor. The MPFM periodically measures the production performance constantly, hourly, daily, weekly, monthly, or annually. Data from the MPFM can indicate increases or decreases in water and oil production and therefore increases or decreases in water cuts. If the MPFM data indicates that the water production has increased and the oil production has decreased, the processor or surface computer system can prompt for a PLT log to be run to determine if intervention is beneficial and/or to reevaluate the areas of the formation categorized as high oil-producing and high water-producing. The apparatus can be used to intervene. The apparatus100aligns the plug sub-system124(e.g., the clad carrier128) with an opening178,180and/or and ICD158in the blank pipe156. The processor110then actuates the plug sub-system124to apply the clad126to the inner face of the blank pipe156. The clad126is mounted by a setting tool (not shown) of the plug sub-system. The setting tool translates the clad126towards the inner surface of the blank pipe156so that the clad is adjacent the opening178,180and/or ICD158. The setting tool then applies a hydraulic or mechanical force to the clad126to increase the diameter of the clad126. The force may be hydraulic or mechanical. The clad126expands such that the entirety of the clad126lies flush with the inner surface of the blank pipe and remains mounted to the blank pipe and the opening178,180and/or ICD158is sealed by the clad126. The mechanical forces of the metal in the clad126maintain the expanded position after the mechanical or hydraulic force is removed. The clad can be made of metals with high ductility sufficient to allow the clad to expand to the internal diameter of the blank pipe and remain in the expanded configuration. The clad may be coated in oil or water-swelling elastomers to improve sealing. Some plug sub-systems include a plug carrier and plugs. In some cases, the plugs are of various sized to plug the openings and the ICDs. The plugs can be applied to the ICDs and/or openings to stop the inflow of a fluid from the formation. The plugs are made of metal, elastomers, or a combination thereof. The plugs may be expandable. A plug sub-system having a plug is described with further reference toFIG.6. FIG.4is a flowchart of a method200for generating an opening in a blank pipe. The method200is described with reference to the system150described inFIGS.3A-3E, however, the method200can be used with any other system or apparatus. First, a horizontal wellbore152is formed and an uncemented blank pipe156(e.g., a blank pipe) is arranged in the horizontal wellbore152. Packers162are arranged around the blank pipe156and isolate portions168of the blank pipe156, each portion168having at least one ICD158. The portions may be about 200 feet (ft) to about 600 ft in length. The packers162are therefore also spaced about 200 ft to about 600 ft apart. The formation154is analyzed to estimate or identify high-water producing areas in the formation and high-oil producing areas of the formation. The processor110generates estimates water cuts in all areas of the formation based on wellbore data. Areas with an estimated water cut 0% to about 20% (e.g., 0% to about 30%) are designated as high-oil producing areas of the formation and areas with an estimated water cut of 50% or more are designated as high-water producing areas of the formation. The portions168of the blank pipe156that correspond to (e.g., are arranged in) the areas of high-water and high-oil are determined by the processor110or by the computer system. A model is then generated, by the processor110or other computer system connected to the processor, to determine if intervention would be economically valuable. An operator may intervene to determine the economic value of actuating the apparatus100to increase oil contribution and/or decrease water contribution. The model determines the location and size of the openings to be milled by the mill sub-system102and determines the openings and ICDs to be sealed by the plug sub-system124. For example, the first portion of the blank pipe may be arranged in a high-oil producing area of the formation whereas the second portion of the blank pipe may be arranged in a high-water producing area of the formation. In such a case, the processor, with the model, identifies the first portion of the blank pipe for milling operations and identifies the second portion of the blank pipe for plugging operations. The milling of an opening in a portion arranged in a high-oil producing area of the formation provides an alternate path for the oil in the formation to bypass the ICD and flow directly into the interior volume160of the blank pipe without a pressure drop and without throttling the fluid flow. The closing or plugging of an opening or ICD in the blank pipe prevents the inflow of water into the interior volume160of the blank pipe and reduces the amount of water in the recovered fluid. In the system150, the second portion168band the fourth portion168dof the blank pipe156are arranged in high-oil producing areas of the formation154. Thus, the second portion168band fourth portion168dare identified by the processor110as portions168of the blank pipe156that will be milled by the apparatus100. In the system150, there are no areas of the formation154that are identified as high-water producing, prior to the insertion of the apparatus100, however, in some systems, portions of the blank pipe arranged in high water-producing areas of the formation are identified in the initial evaluation of the well (e.g., the well model), prior to apparatus insertion. After identifying the high-oil producing areas and the high-water producing areas of the formation154and the corresponding portions168of the blank pipe156, the apparatus100is inserted into the wellbore152by a wireline174. The alignment sub-system123moves the apparatus100within the blank pipe156to align the milling sub-system102with the second portion168bof the blank pipe156that is arranged in the identified high-oil producing area of the formation154. A camera arranged on the apparatus may confirm the alignment. In some systems, the portion of the blank pipe that is arranged in the identified high-oil producing area of the formation is a first portion. The processor110determines predefined diameter for an opening on the second portion168bof the blank pipe. The diameter of the opening is determined prior to milling the opening by the processor110, with the model. The processor110analyzes a wellbore model generated based on the wellbore data. The diameter of the opening is large enough to prevent any additional pressure drops across the blank pipe, thereby preventing throttling fluid flow from the formation to the blank pipe. The wellbore data for generating the model may include water cut estimations, oil production data, water production data, PLT data, the water cut of the formation or the areas of the formation, pressure data, well productivity data, temperature data, fluid PVT data, and wellhead pressure data. The processor110then activates the milling sub-system102of the apparatus100such that the opening178is milled in the portion168of the blank pipe156arranged in the high-oil producing area of the formation154. When the milling sub-system102is actuated, the drill bit116rotates and the braces120move from the retracted position (e.g., flush with the housing104of the apparatus100) into the extended position by rotating about a hinge. In the extended position the braces120radially extend from the bottom side121and press the upper side114of the apparatus100towards the inner face of the blank pipe156. The braces120continue to extend as the drill bit116of the milling sub-system102abuts the inner face of the blank pipe156. The drill bit116generates the opening178and continues to enlarge the opening178. To enlarge the opening, the braces120extend radially farther by rotating further about the hinge, thereby pressing the drill bit116deeper into the blank pipe156. In some cases, the drill bit may also translate to enlarge the opening and/or to form a predetermined shape (e.g., an eclipse or an oval). The milling sub-system102continues to enlarge the opening178until the opening178has the predetermined diameter. Such a configuration precisely and non-explosively mills an opening the blank pipe while reducing the risk of cracking the uncemented blank pipe during milling. The opening178is about 10 to 50 times larger than the ICD158(e.g., 20 mm to 300 mm) and does not throttle or restrict the flow of fluid flowing into the interior volume160from the formation154. The milling sub-system continues to mill additional openings in the portions168of the blank pipe156initially identified by the processor110as being arranged in a high-oil producing areas of the formation154. FIG.5is a flowchart for covering an opening in a blank pipe. The method250is described with reference to system150, however, the method250may also be used in other systems or apparatuses. Further, the method250is described herein as proceeding after the method200, however, the method250may occur prior to the method200, concurrently with the method200, or without the method200. The method250includes analyzing, prior to the inflow of oil into the blank pipe, wellbore data to estimate water cuts of areas of the formation. The wellbore data may be used to generate, for example, a well model. The processor110initially identifies potential high-water producing areas of the formation154based on the well model. After the milling sub-system102has milled the openings178,180in the portions168of the blank pipe156, the alignment system123of the apparatus100aligns the plug sub-system with an ICD or opening of a portion of the blank pipe that was identified by the processor as being arranged in a potentially high-water producing area. The system150did not initially identify any portions168of the blank pipe as arranged in high water producing areas of the formation154. In some cases, the processor does initially identify portions of the blank pipe arranged in high-water producing areas, for example, a first or second portion of the blank pipe If a portion is identified as arranged in a high-water producing area of the formation, the apparatus aligns the plug sub-system (e.g., the clad carrier or the plug carrier) with the ICD or opening The processor then actuates the plug sub-system to cover the ICD or opening. The plug sub-system can mount a clad on the inner face of the blank pipe so that the clad covers the ICD and no fluid flows through the ICD from the formation. The clad carrier128includes a setting tool (not shown) that applies the clad126to the inner surface of the blank pipe156. The clad carrier128releases the clad126and the setting tool moves the clad126to the inner surface of the blank pipe156. The clad126is initially formed at a diameter smaller than the inner diameter of the blank pipe156. As the clad126abuts the inner surface of the blank pipe, the setting tool applies a force to the clad126to increase the diameter of the clad126. The clad126expands such that the entirety of the clad126lies flush with the inner surface of the blank pipe and remains mounted to the blank pipe. Some systems insert a plug into the ICD or opening. Covering the ICD and/or opening reduces the inflow of water into the interior volume of the blank pipe, thereby increasing the oil to water ratio of the recovered fluid. In addition, this system reduces the amount of ground water removed from the formation. At this stage, the portions168of the blank pipe156have been opened or covered based on the initial identifications of the processor110. These initial identifications were based on well modelling. During oil recovery, the status of the areas in the formation can change, for example, areas of the formation154that were initially high-oil producing areas may be depleted over time and transition into high-water producing areas or some areas in actuality. In some cases, the measured water cuts may be different than the well model predicted or there may be other obstacles inhibiting movement of oil or water from the formation to the blank pipe. As such, real time data is analyzed by the processor110or the computer system to determine the current state of the well and update the identified areas of the formation. The processor110analyzes production data to analyze the current status of the well. Production data can include measured or calculated water cuts, current well pressure data, recovered fluid composition, PLT log results, and other measured sensor data to determine the areas of high-oil production and areas of high-water production. Based on the current data, the processor110identifies new areas that are high-oil producing and new high-water producing areas. The processor110also confirms any high-oil or high-water producing areas that were identified in the initial well model. For example, in the system150, the second portion168bof the blank pipe156was initially identified as in a high-oil producing, however, as the oil moved from the formation to the interior volume160of the blank pipe156, the area of the formation154transitioned into a high-water producing area. The processor110detected this transition by analyzing the production data (e.g., measured or calculated water cuts) and determined that the second portion168bis arranged in a high-water producing area. In response to this determination, alignment sub-system123of the apparatus100aligns the plug sub-system124with the second portion168band the processor110actuates the plug sub-system124. The plug sub-system mounts a clad126onto the inner face of the blank pipe156so that the ICD158and the opening178are covered by the clad126. In some cases, the clad only covers the opening178. Some plug sub-systems include plugs and plug carriers. The plug sub-system124applies the plug to the ICD and/or the opening when the plug sub-system is actuated by the processor110. FIG.6is cross-sectional side view of a system300with an apparatus302that has milled openings178,180, applied dads126, and applied a plug182to the blank pipe156. The system300and apparatus302are substantially similar to the system150and apparatus100, however, the apparatus302has a plug sub-system304that includes both a clad carrier128and a plug carrier306. The clad carrier128carries and mounts the clad126on the inner surface of the blank pipe, as described with reference toFIG.3D. The plug carrier306includes a plug308having expandable setting keys (note shown). The plug308is releasably mounted to the plug carrier306. A plug308can be placed in the blank pipe156to seal off downstream portions of the blank pipe156from fluid connection with the surface via the blank pipe156. The plug308is advantageously used when the portion of the blank pipe deepest in the wellbore is arranged in a high water-producing area of the formation154. In some cases, the deepest portion of the blank pipe and the adjacent portions of the blank pipe are arranged in high water-producing areas. InFIG.6, the clad126and plug308are shown as mounted in or on the blank pipe156. The plug carrier206holds the plug308and expandable setting keys in a compressed configuration during transport and alignment. The keys of the plug308are expandable to at least the diameter of the blank pipe156. To mount the plug308, the processor110identifies the high-water producing areas of the formation and identifies the portions of the blank pipe156arranged in the high water-producing areas of the formation154. The processor110then determines if a plug308can be used to fluidly isolate the portions of the blank pipe arranged in the high water-producing areas. The processor110prompts the alignment sub-system to align the plug308of the plug subsystem304with the identified portion of the blank pipe. The plug308is arranged at an uphole boundary of the portion of the blank pipe so that the plug308is upstream of any openings or ICDs defined in the identified portion of the blank pipe156. The processor110then prompts the plug sub-system to release the compressed plug308using a plug running member (not shown) that mechanically electrically, or hydraulically places and activates the plug setting so that the expandable keys of the plug engage with the inner surface of the blank pipe. The plug308, without the plug carrier306, expands to abut the inner surface of the blank pipe156and seal the identified portion of the blank pipe, and any other portion downhole of the identified portion, from the surface of the wellbore. In some cases, the plug sub-system of the system is a separate from the apparatus. In such a system, the apparatus mills openings in the portions of the blank pipe arranged in high oil-producing areas and the apparatus is removed from the wellbore. The plug sub-system is then inserted into the wellbore and applies clads and/or plugs to the blank pipe to mitigate water inflow from high water-producing areas of the formation. In some systems, the plug sub-system is deployed prior to the apparatus. The plug sub-system further includes a second processor and an alignment assembly controlled by the second processor. The second processor is connected to the (first) processor of the apparatus and/or to a computer system at the surface. The second processor is substantially similar to the first processor. In some cases, the processor can also identify high-oil producing area of the formation that performs better than initially modeled. The processor can then actuate the milling sub-system to form a second, third, or fourth opening in the corresponding portion of the blank pipe wellbore to increase the amount of oil flowing into the interior volume of the blank pipe. The new openings can be formed by aligning the milling subs system with the identified portion of the blank pipe. The processor then actuates the milling sub-system to form a second, third, or fourth opening in the identified portion of the blank pipe. While a method that mills all initial openings then closes openings or ICDs has been describes, some systems mill and cover openings or ICDs as the apparatus moves towards the end face of the wellbore. For example, rather than milling an opening at the second portion and the fourth portion then applying a clad to the third portion, the system can mill an opening in the second portion, apply a clad to the third portion, then mill an opening in the fourth portion. In some cases, the plug sub-system seals and/or plugs ICDs in the blank pipe prior to milling any openings. In some cases, the initial well model is generated based on the wellbore data and analyzed by the processor, but no adjustments (e.g., milling or plugging) are made to the blank pipe based on the initial well model. Rather, the apparatus mills or plugs openings based on both the production data gathered during oil recovery and the wellbore data gathered prior to oil recovery. In some systems, apparatus does not perform initial milling and closing based on a well model but rather is deployed during oil production and determines high-oil producing areas and high-water producing areas based on the current data generated from the oil recovery operation. Some milling sub-systems form more than one opening in a portion of the blank pipe. The milling sub-assembly can include multiple drill bits. In some systems, the apparatus rotates relative to the blank pipe to align the drill bit with the inner face of the blank pipe. In some cases, the processor also actuates the alignment sub-system, the milling sub-system, and/or the plug sub-system based on the estimated structural integrity of the blank pipe. For example, the first portion of the blank pipe arranged in a high-oil producing area of the formation may have multiple openings formed by the milling sub-system of the apparatus. While the openings facilitate the inflow of oil into the blank pipe, multiple openings arranged closely could compromise the integrity of the blank pipe. As such, the processor may prompt the alignment sub-system to rotate or translate the milling sub-system in the blank pipe to spread the openings along the first portion of the blank pipe, thereby reducing the risk of structural failure. In some apparatuses, the braces are extendable lifts or collapsible arms. In some milling sub-systems, the braces are a lift arranged at on the upper side of the apparatus at a base of the drill bit. The lift is configured to extend away from the housing of the apparatus and move the drill bit towards an inner face of the blank pipe. In such an embodiment, the hinged arms may be omitted. In some systems the ICDs are small holes, check valves, or pressure valves. In some systems the dads and/or plugs are removable by the plug sub-system. Like reference symbols in the various drawings indicate like elements. A number of embodiments have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the system and methods. Accordingly, other embodiments are within the scope of the following claims. | 40,201 |
11859473 | DETAILED DESCRIPTION Example systems and methods for automatic in-situ gas lifting in a multilateral well using inflow control valves are described. Unless explicitly stated otherwise, components and functions are optional and may be combined or subdivided. Similarly, operations may be combined or subdivided, and their sequence may vary. In the following detailed description of embodiments of the disclosure, numerous specific details are set forth in order to provide a more thorough understanding of the disclosure. However, it will be apparent to one of ordinary skill in the art that the disclosure may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description. Throughout the application, ordinal numbers (e.g., first, second, or third) may be used as an adjective for an element (that is, any noun in the application). The use of ordinal numbers is not to imply or create any particular ordering of the elements nor to limit any element to being only a single element unless expressly disclosed, such as using the terms “before,” “after,” “single,” and other such terminology. Rather, the use of ordinal numbers is to distinguish between the elements. By way of an example, a first element is distinct from a second element, and the first element may encompass more than one element and succeed (or precede) the second element in an ordering of elements. Generally, oil wells cease to flow when the reservoir energy is not sufficient to overcome the hydrostatic pressure exerted by the fluid column. As the water cut in the produced fluid increases over a period of time or the reservoir pressure drops, the reservoir energy may not be sufficient to overcome the hydrostatic pressure of the fluid column. Typically, to revive the well, gas is injected from the surface into the production tubing in order to reduce the density of the fluid column, which in turn reduces the hydrostatic pressure of the fluid column and forces the fluid to flow to the surface. However, this traditional approach to gas lifting results in frequent operational interruptions caused by equipment maintenance. A system for automatic in-situ gas lifting in a multilateral well using inflow control valves (hereinafter also “ICVs”) provides improvements over the conventional gas lift systems by minimizing the need for equipment maintenance and the interruptions in the operations of the well and the surface facility. The in-situ gas lifting system may include a completion scheme that enables the utilization of multiple wellbores in an oil well. The multiple wellbores in such an oil well may be vertical, horizontal, at an angle, or a combination thereof. Such multiple wellbores in an oil well are also called “wellbore branches,” “lateral wellbores,” or simply “laterals.” The completion scheme that enables the utilization of multiple wellbores in the oil well may be called a “multilateral well.” A multilateral well with access to a downhole natural gas source via one or more of the laterals may utilize the gas from the downhole natural gas source to lighten the fluid column. This allows the prolonging of the life of the well by sustaining the oil production or facilitating additional oil production from the well without relying on an artificial injection of gas. The in-situ gas lifting system automatically actuates one or more ICVs based on a fluid pressure gradient value determined using pressure data captured by sensors placed upstream of the one or more ICVs within the multilateral well. In addition to the advantages stemming from the use of a gas from a natural source without relying on an artificial gas injection to cause the flow of oil in the multilateral well, the in-situ gas lifting system provides the benefit of restricting or stopping the gas production, when desired, by hydraulically or electrically adjusting or closing the ICV located in the lateral connected to the gas source. This allows for an enhanced control of the well production and equipment. FIG.1is a schematic illustration of a multilateral well environment, according to one or more example embodiments. The well environment100includes a well102extending from the surface into a target zone of a formation, such as an oil reservoir122. InFIG.1, the oil reservoir122is also identified as Zone B. Zone B is an under-saturated oil zone. Although the discussion ofFIG.1hereafter talks about an oil reservoir122, those of ordinary skill in the art will appreciate that the reservoir may also be a gas reservoir. The well102is a multilateral well which includes a plurality of lateral wellbores (hereinafter also “laterals”), such as laterals104,106, and108. The laterals may be horizontal, vertical, at an angle, or a combination thereof. The laterals106and108are placed across the oil reservoir122. The oil reservoir122is under-saturated. The lateral104is placed across a gas condensate or volatile oil source120, identified as Zone A inFIG.1(hereinafter also “the gas source120,” “the gas zone,” or “the gas source”). In some example embodiments, each lateral is equipped with an inflow control valve (hereinafter also “ICV”) to facilitate and control the flow from each lateral. In some example embodiments, the fluid (e.g., oil) flow from a lateral is controlled by placing an ICV above the window (e.g., opening or aperture) where the lateral connects to the main bore or another lateral. For example, as shown inFIG.1, the lateral104is the main bore. Natural gas may enter the lateral104through perforation118of the lateral104. Perforations118are sharp shots that allow access/communication between the formation and the wellbore. ICV110, placed above the perforation118, controls the flow of gas from the gas source120through the perforation118in the case of a cased hole completion, or through the lateral104in the case of an open hole completion (e.g., a screen-less completion) to the surface. ICV112is placed within the lateral104, above the window through which the oil flows from the lateral106to the lateral104. The ICV112controls the oil flow from the lateral106through the lateral104to the surface. Similarly, ICV114is placed within the lateral104, above the window through which the oil flows from the lateral108to the lateral104. The ICV114controls the oil flow from the lateral108through the lateral104to the surface. As shown inFIG.1, each of the ICVs110,112, and114has an isolation packer (e.g.,116,130, and132) placed above the respective ICV to eliminate behind-pipe flow and to cause the gas or the mixture of oil and gas to flow through the respective ICV. For example, as gas flows through the lateral104, an isolation packer placed above the ICV110precludes the uphole flow of gas around the ICV110. Instead, the gas is forced to flow solely through the ICV110when the ICV110is open. Further, as the gas flows through the open ICV110, it mixes with the oil received from the oil reservoir122via the lateral106, in zone124of the lateral104. A second isolation packer placed above the ICV112precludes the uphole flow of the oil and gas mixture around the ICV112. Instead, the oil and gas mixture is forced to flow solely through the ICV112when the ICV112is open. Similarly, as the oil and gas flows through the open ICV112, it mixes with the oil received from the oil reservoir122via the lateral108, in zone126of the lateral104. A third isolation packer placed above the ICV114precludes the uphole flow of the oil and gas mixture around the ICV114. Instead, the oil and gas mixture is forced to flow solely through the ICV114when the ICV114is open. The ICVs shown inFIG.1may be actuated (e.g., partially opened, fully opened, or closed) automatically based on a fluid pressure gradient value determined using pressure data captured by a plurality of downwhole sensors placed upstream of the ICVs within the multilateral well102. The plurality (e.g., two) of downwhole sensors are placed in area128of the well102to measure the pressure of the fluid passing through the tubing of the multilateral well102. In some example embodiments, the plurality of sensors are placed at least 100 ft. vertically apart from each other, above a top mixing point during flowing condition. The top mixing point is an area above the top-most ICV (e.g., the ICV114) where the mixing of oil, water and gas occurs within the well102. In some example embodiments, the plurality of downwhole pressure sensors, the ICVs110,112, and114, and an analysis module are included in an in-situ gas lifting system for in-situ gas lifting of fluid in the multilateral well102. The pressure data may be communicated from the downwhole pressure sensors to a surface panel through an electric cable. The surface panel may transmit the pressure data to the analysis module. The analysis module determines whether, based on the pressure data, one or more of the ICVs110,112, and114should be opened or closed to facilitate or control the fluid flow to the surface, and transmits an instruction to the surface panel to actuate the one or more of the ICVs110,112, and114. In some instances, the surface panel opens or closes an ICV through an electric signal transmitted via an electric wire connecting the surface panel and the ICV, in response to the instruction transmitted by the analysis module to the surface panel. In some instances, the surface panel opens or closes the ICV through the use of hydraulic power (e.g., a hydraulic wire or cable transports the hydraulic fluid to the ICV to actuate it) in response to the instruction transmitted by the analysis module to the surface panel. The in-situ gas lifting system may include a computer system that is similar to the computer systems900and914described with regard toFIGS.9A and9B, respectively, and the accompanying descriptions. FIGS.2A,2B,2C, and2Dare diagrams that illustrate inflow control valves used in an in-situ gas lifting system, according to one or more example embodiments. As stated above with respect toFIG.1, in some example embodiments, each lateral of the multilateral well is equipped with one or more ICVs which can be partially opened, fully opened, or closed for facilitating and controlling flow from each lateral. Gas can flow from a rich gas zone via a lateral and through an opened ICV to another lateral where natural lifting of fluid received from an oil reservoir occurs. Two example types of ICVs that may be used in the in-situ gas lifting system are illustrated inFIGS.2A and2B, andFIGS.2C and2D, respectively.FIG.2Adepicts a close-ended ICV in an open position.FIG.2Bdepicts the close-ended ICV in a closed position. As shown inFIG.2A, the close-ended ICV is equipped with a bull-nose210which precludes the gas from the gas source to enter the close-ended ICV through its end. The close-ended ICV may be used as part of an ICV completion system that includes an isolation packer218. The close-ended ICV completion system may be used in a lateral that crosses a gas zone. When the close-ended ICV is in an open position, one or more ICV ports212are open to allow gas to flow into the close-ended ICV. The gas enters the close-ended ICV through the one or more open ICV ports212, and flows toward a mixing point of the oil well where the gas is mixed with the oil received from another lateral. As shown inFIG.2A, the gas214flows through the open close-ended ICV, and enters tube222in area216. Arrow220represents the gas flowing through the tube222. As shown inFIG.2B, the close-ended ICV is in a closed position. When the close-ended ICV is in a closed position, one or more ports242of the close-ended ICV are closed. No gas enters the close-ended ICV through its end or through the one or more closed ports242. The isolation packer244prevents behind-pipe flow of the gas. As a result, no gas flows upstream through the close-ended ICV completion system when the close-ended ICV is in the closed position. FIG.2Cdepicts a one-way ICV in an open position.FIG.2Ddepicts the one-way ICV in a closed position. The one-way ICV is equipped with a flapper or a ball-seat224. The one-way ICV may be used as part of an ICV completion system that includes an isolation packer238. The one-way ICV completion system may be used in a lateral that crosses an oil reservoir. The one-way ICV completion system allows oil flow in one direction, as shown by arrow228inFIG.2Cand arrow252inFIG.2D. The ball226in the ball-seat224precludes the oil from exiting the one-way ICV through the ball-seat224and, as a result, prevents cross-flow between the laterals in the oil reservoir. When the one-way ICV is in an open position, one or more ICV ports232are open to allow additional fluid234to flow into the one-way ICV. The additional fluid234enters the one-way ICV through the one or more open ICV ports232, and flows toward a mixing point of the oil well where the fluid is mixed with the gas received from another lateral. As shown inFIG.2C, the additional fluid234flows through the open one-way ICV, and enters tube230in area236where it mixes with the fluid that enters the one-way ICV through the ball-seat224. As shown inFIG.2D, the one-way ICV is in a closed position. When the one-way ICV is in a closed position, one or more ports242of the one-way ICV are closed. No oil enters the one-way ICV through the one or more closed ports256. Fluid from the oil reservoir enters the closed one-way ICV solely through the ball-seat248. Arrow252represents the oil that enters the closed one-way ICV through the ball-seat248and flows upstream through tube254. The ball250in the ball-seat248precludes the fluid252from exiting the closed one-way ICV through the ball-seat248and, as a result, prevents cross-flow between the laterals in the oil reservoir. The isolation packer258prevents behind-pipe flow of the fluid. As a result, the fluid252will flow upstream solely through the one-way ICV completion system. In some example embodiments, one-way ICVs (e.g., flapper ICVs and ball-seat ICVs) are utilized in both the laterals that cross the gas zone and the laterals that cross the oil reservoir. However, because the flapper ICVs and the ball-seat ICVs may be more prone to failure when subjected to high pressure, close-ended ICVs are often used in laterals placed across the gas zone to withstand the high pressure of the gas in the gas zone. FIG.3is a flow diagram that illustrates an algorithm for enabling automatic in-situ gas lifting using inflow control valves, according to one or more example embodiments. The in-situ gas lifting system may cause automatic in-situ gas lift of fluid in one lateral of a multilateral well based on using an ICV that controls the flow of a gas from a natural source of gas through another lateral of the multilateral well. The algorithm may be used, in some example embodiments, by the in-situ gas lifting system to manage the timely introduction of gas or light fluid, when needed, before fluid ceases to flow from the multilateral well. The use of the algorithm preserves the momentum of the flow and reduces downtime in the operation of the multilateral well. In some example embodiments, an algorithm based on downhole sensors pressure data is used to perform the automatic in-situ gas lift of the fluid. Two sensors are placed at least 100 ft. apart vertically, above the top-most ICV in the lateral (e.g., the main bore) where the mixing of oil, water, and gas occur. The distance of at least 100 ft. allows for an accurate determination of a fluid pressure gradient value. The fluid pressure gradient value is a number that describes the rate of pressure change with respect to elevation (or vertical distance) at a single location due to the presence of a single or different fluids. The algorithm utilizes the annulus (e.g., the space between the inner casing and outer tubing) pressure as an estimate of the dynamic reservoir pressure at each lateral. This value can be used to calculate the pressure at the wellhead based on the fluid gradient as shown below: Gdp=P2-P1D(1)Pwf=Pfwh+Gdp·D+ΔPf(2) where Gdpis calculated above the top mixing point during flowing conditions, where P1and P2are tubing pressure values from two sensors with at least 100 ft. vertical spacing in-between, and where D is the distance between the two sensors. The value ΔPfis the pressure loss in the tubing due to friction and can be calculated using flow correlations for multi-phase flow, such as Beggs and Brill, Hagedorn and Brown, or Petalas and Aziz. The algorithm is designed to trigger automatic valve closure or opening depending on a calculated pressure gradient tolerance value. The calculation process is iterative. Wells tend to cease flowing when the flowing wellhead pressure is not high enough to overcome backpressure. The backpressure is a surface pressure value that is determined based on the processing facility design, the distance from the facility, and the number of connected wells on the same flowline manifold. When different wells with different flowing wellhead pressures are connected on the same flowline, they tend to affect the backpressure induced on every single one of them. Typically, stronger wells with high gas oil ratios cause additional backpressure on weaker and lower gas oil ratio wells as they are all connected on the same flowline and are in hydraulic communication. The algorithm is designed to trigger automatically and open ICV110to allow the gas to be mixed with the stream and increase the flowing wellhead pressure. When the well is first put on stream, a reference gradient (Gdpr) is recorded. This reference gradient is determined based on sensor pressure values P1and P2captured with a water-free fluid column, when the wellhead pressure is the maximum wellhead pressure under natural flow at a specific surface choke setting. When the pressure gradient increases (e.g., the fluid column becomes heavier due to the introduction of water) and the flowing wellhead pressure decreases, a new gradient value (Gdp) is recorded. The algorithm benchmarks the decrease in the flowing wellhead pressure and subtracts it from the backpressure in an iterative process. The ICV used to prevent or restrict flow from the gas zone is opened at an initial, pre-determined position to allow the flow of gas or light fluid, to lighten the fluid column, to reduce the pressure gradient, and to increase the flowing wellhead pressure. The calculation process is repeated again, and the gradient will be continuously updated and compared to the tolerance in order to determine whether to open or choke (e.g., close) the gas-source ICV as shown inFIG.3. Gd is the pressure gradient. Gd tolerance is the tolerance value that is pre-set to be benchmarked with respect to the subtracted value between the Gdp, the dynamic pressure gradient during the flowing condition, and the Gdpr, reference pressure gradient. PBpis the backpressure, which is a constant value. It is also known as the downstream pressure. Pwfis the flowing wellhead pressure, also known as the upstream pressure. P tolerance is a tolerance value that is pre-set as a benchmark between the Pwfand the PBp. In other words, it is a value that indicates how much offset is desired to facilitate natural flow at a desired production rate. As illustrated inFIG.3, in some example embodiments, the algorithm includes two parts: a pressure gradient algorithm302and a wellhead pressure algorithm304. At step306of the pressure gradient algorithm302, the in-situ gas lifting system sets the Gd and P tolerance values, and the PBpand Gdprvalues. Then, at step308, the in-situ gas lifting system calculates the dynamic Gdpat the top mixing point. At step310, the in-situ gas lifting system determines whether the difference between Gdpand Gdpris greater than the Gd tolerance. If the difference between Gdpand Gdpris not greater than the Gd tolerance, then the in-situ gas lifting system ensures, at step312, that the gas-source ICV is fully closed. If the difference between Gdpand Gdpris greater than the Gd tolerance, then the in-situ gas lifting system proceeds to step322of the wellhead pressure algorithm304. If, at step312, the in-situ gas lifting system determines that the gas-source ICV is fully closed, the in-situ gas lifting system performs step308again. If, at step312, the in-situ gas lifting system determines that the gas-source ICV is not fully closed, the in-situ gas lifting system proceeds to step314. At step314, the in-situ gas lifting system determines whether the difference between Gdpand Gdpris within ten percent of the Gd tolerance. If at step314, the in-situ gas lifting system determines that the difference between Gdpand Gdpris within ten percent of the Gd tolerance, the in-situ gas lifting system proceeds to step316. At step316, the in-situ gas lifting system records the ICV choke size as the optimum choke size and holds it to lift the well. If at step314, the in-situ gas lifting system determines that the difference between Gdpand Gdpris not within ten percent of the Gd tolerance, the in-situ gas lifting system proceeds to step318. At step318, the in-situ gas lifting system sends a signal from a sensor control panel to the ICV control panel to choke the gas-source ICV by a pre-defined value (e.g., increment). After performing either step316or step318, the in-situ gas lifting system proceeds to step320, at which the in-situ gas lifting system waits for a certain period of time (e.g., five hours) for the fluid to stabilize. After the certain period of time, the in-situ gas lifting system performs step308again. As stated above, if the in-situ gas lifting system determines, at step310, that the difference between Gdpand Gdpris greater than the Gd tolerance, then the in-situ gas lifting system proceeds to step322of the wellhead pressure algorithm304. At step322, the in-situ gas lifting system observes Pwh. At step324, the in-situ gas lifting system determines whether the difference between Pwhand PBpis greater than or equal to the P tolerance. If the in-situ gas lifting system determines that the difference between Pwhand PBpis greater than or equal to the P tolerance, then the in-situ gas lifting system performs step322again. If the in-situ gas lifting system determines that the difference between Pwhand PBpis less than the P tolerance, then the in-situ gas lifting system proceeds to step326. At step326, the in-situ gas lifting system sends a signal from the sensor control panel to the ICV control panel to open the gas-source ICV to a predetermined position. FIG.4is a diagram400that illustrates the operation of an in-situ gas lifting system when gas lifting is not performed, according to one or more example embodiments. As shown inFIG.4, lateral402crosses Zone A414. Zone A414is a gas or volatile oil zone. A close-ended ICV408is located in the lateral402above area418of the lateral402. Laterals404and406cross Zone B416. Zone B416is an oil reservoir. A one-way ICV410is placed within the lateral402above window420that connects the lateral404to the lateral402, and through which oil426flows from the Zone B416into the lateral402via the lateral404. A one-way ICV412is placed above window422that connects the lateral406to the lateral402, and through which oil428flows from the Zone B416into the lateral402via the lateral406. When oil (or a mix of oil and water) flows freely from the lateral404through the ICV410or from the lateral406through the ICV412to the surface, the in-situ gas lifting system does not employ in-situ gas lifting using gas (or volatile oil) from the Zone A414via the lateral402. The energy of the oil reservoir in the Zone B416is sufficient to overcome the hydrostatic pressure exerted by the fluid column, the oil from Zone B416flows to the surface via the lateral404or the lateral406, and there is no need to lighten the fluid column by introducing gas from the Zone A414. The ICV408is kept closed. The isolation packer430prevents behind-pipe flow of the gas424that has entered the lateral402from the Zone A414via the area418of the lateral402. As a result, no gas (or volatile oil) flows upstream through the ICV408. Further details with respect to the operation of the in-situ gas lifting system are described below with respect toFIG.8. FIG.5is a diagram500that illustrates the operation of the in-situ gas lifting system when gas lifting is performed, according to one or more example embodiments. As shown inFIG.5, lateral502crosses Zone A514. Zone A514is a gas or volatile oil zone. A close-ended ICV508is located in the lateral502above area518of the lateral502. Laterals504and506cross Zone B516. Zone B516is an oil reservoir that is or has become under-saturated. A one-way ICV510is placed within the lateral502above window520that connects the lateral504to the lateral502, and through which oil526flows from the Zone B516into the lateral502via the lateral504. A one-way ICV512is placed above window522that connects the lateral506to the lateral502, and through which oil528flows from the Zone B516into the lateral502via the lateral506. When one or both of the laterals504and506begin cutting water, the multilateral well ceases to flow if the reservoir pressure is not sufficient to lift the fluid to the surface (Pr<PHydrostatic). In this case, gas lifting using gas from the Zone A514 is performed. The ICV508included in the lateral502is opened to supply the fluid column with gas524(or volatile oil) to lighten the heavy fluid column and to reduce the hydrostatic pressure (Pr>PHydrostatic) in order to facilitate flow to the surface. The gas524enters the lateral502in area518of the lateral502. An isolation packer536placed above the ICV508eliminates behind-pipe flow of the gas524and ensures that the open ICV508is the only opening for the gas524to flow. Arrow530represents the gas flowing uphole in the tube532between the ICV508and the ICV510. If the one-way ICV510placed above the window520is open, the oil526that flows from the lateral504enters the ICV510through one or more open ICV ports of the ICV510and mixes with the gas530. The gas530lightens the heavy fluid column and facilitates the flow to the surface, as shown by arrow534. If the one-way ICV510is closed, the one or more ICV ports of the ICV510are closed and do not allow inflow of oil into the tube532via the lateral504. However, the gas530may continue to flow through the one-way ICV510(as shown inFIG.2D). Further, if the one-way ICV512placed above the window522is open, the oil528that flows from the lateral506enters the ICV512through one or more open ICV ports of the ICV512and mixes with the gas530(or a mix of oil and gas534that is created when the gas524mixes with the oil526). The gas530lightens the heavy fluid column and facilitates the flow to the surface. If the one-way ICV512is closed, the one or more ICV ports of the ICV512are closed and do not allow inflow of oil into the tube532via the lateral506. However, the gas530or the mix of oil and gas534may continue to flow through the one-way ICV512(as shown inFIG.2D). FIG.6is a block diagram that illustrates an in-situ gas lifting system, according to one or more example embodiments. InFIG.6, the in-situ gas lifting system602is operatively connected to a client device628and a data repository624. The in-situ gas lifting system602is shown as including one or more ICV completion systems604. The ICV completion system604includes downhole pressure sensor (616,618), an analysis module620, and a surface panel622. In one or more embodiments, an ICV completion system604may be placed in a first lateral of a multilateral well to utilize the flow of a downhole natural gas from the first lateral to reduce the density of a fluid flowing from a second lateral and to cause the natural lift of the fluid to the surface. The downhole pressure sensors616,618are located at least 100 ft. vertically apart within a main bore (or a lateral), above the top-most ICV, and are configured to periodically measure (e.g., capture) fluid pressure data. The fluid pressure data measured by the sensors616,618is stored as sensor data626in a data repository624. The data repository may be any type of storage, such as non-persistent storage (e.g., random access memory (RAM), cache memory, or flash memory), one or more persistent storage (e.g., a hard disk), or any other suitable type of memory capable of storing data within data structures such as arrays, lists, tables, etc. The analysis module620(e.g., a processor) dynamically determines a fluid pressure gradient value associated with the multilateral well based on the periodically captured pressure data, and determines whether the ICVs included in the one or more ICV completion systems604should be opened or closed bases on the fluid pressure gradient value. A shown inFIG.6, the ICV completion system604includes an ICV606, ICV sensor(s)608, a communication module610, an isolation packer612, and an electric wire or hydraulic cable614. The components of the in-situ gas lifting system602are operatively connected and are configured to communicate with each other (e.g., via a wire, a cable, a bus, shared memory, a switch, wirelessly, etc.). The ICV sensor(s)608may include a pressure sensor or a temperature sensor. The communication module610transmits and receives communications (e.g., signals) to and from the analysis module620via a surface panel622. In some example embodiments, the downhole pressure sensors616,618communicate the measured pressure data to the surface panel622through an electric cable614. The surface panel622may transmit the pressure data to the analysis module620through an electric cable614or wirelessly. The analysis module620determines whether, based on the pressure data, one or more of the ICVs606should be opened or closed to facilitate or control the fluid flow to the surface, and transmits an instruction to the surface panel622to actuate the one or more of the ICVs606. In some instances, the surface panel opens or closes an ICV through an electric signal transmitted via an electric wire614connecting the surface panel622and the ICV606, in response to the instruction transmitted by the analysis module620to the surface panel622. In some instances, the surface panel622opens or closes the ICV606through the use of hydraulic power (e.g., a hydraulic cable transports the hydraulic fluid to the ICV to actuate it) in response to the instruction transmitted by the analysis module620to the surface panel622. The analysis module620may be implemented using hardware (e.g., one or more processors of a machine) or a combination of hardware and software. For example, the analysis module620may configure a processor to perform the operations described herein for the analysis module620. According to another example, the analysis module620is a hardware processor that performs the operations described herein for the analysis module620. In some example embodiments, the analysis module620may be distributed across multiple machines or devices. The in-situ gas lifting system604is also configured to communicate with a client device628that includes the user interface630. In some example embodiments, a user of the client device628accesses the in-situ gas lifting system604via the user interface630. The user may, for example, make configuration changes to the one or more modules included in the in-situ gas lifting system604. The client device628is also configured to communicate with the data repository624to access and store data. FIGS.7and8are flowcharts illustrating operations of the in-situ gas lifting system in performing a method700for in-situ gas lifting of a fluid in a multilateral well, according to one or more example embodiments. Operations of the method700may be performed using the components described above with respect toFIG.6. One or more blocks inFIGS.7and8may be performed by a computing system such as that shown and described below inFIGS.9A and9B. While the various blocks inFIGS.7and8are presented and described sequentially, one of ordinary skill in the art will appreciate that some or all of the blocks may be executed in different orders, may be combined or omitted, and some or all of the blocks may be executed in parallel. Furthermore, the blocks may be performed actively or passively. At Step702, a plurality of downhole sensors (e.g., the downhole pressure sensors616and618) periodically capture pressure data associated with the multilateral well. In some example embodiments, the plurality of downhole sensors include two sensors located at least 100 feet apart vertically, above a top mixing point during flowing condition. At Step704, a processor (e.g., the analysis module620ofFIG.6) dynamically determines a pressure gradient value associated with the multilateral well based on the periodically captured pressure data. The pressure gradient value may be dynamically determined based on a difference between a first pressure value, determined by a first sensor of the two sensors located at least 100 feet apart vertically above the top mixing point during flowing condition, and a second pressure value, determined by a second sensor of the two sensors. At Step706, a first ICV (e.g., the ICV606) that is placed within a first lateral automatically controls a flow of a gas from a downhole natural gas source into the multilateral well based on the dynamically determined pressure gradient. In some example embodiments, the ICV includes a close-ended ICV equipped with a bullnose. The close-ended ICV prevents uncontrolled gas production through the first lateral. In some example embodiments, a second ICV disposed within the first lateral, above a window that connects the second lateral to the first lateral, controls the flow from the second lateral. The plurality of downhole sensors are located upstream of the first ICV and the second ICV. In various example embodiments, the first ICV is a close-ended ICV. In some instances, a second ICV, which is a one-way ICV, is placed within the first lateral, above a window that connects the second lateral to the first lateral, to control the flow from the second lateral. In some instances, a second ICV, which is a one-way ICV, is placed within the second lateral to isolate the second lateral. In certain instances, the one-way ICV is equipped with a flapper. In certain instances, the one-way ICV is equipped with a ball-seat. In certain example embodiments, the first ICV is a one-way ICV. In some instances, a second ICV is another one-way ICV that is placed within the second lateral to isolate the second lateral. In some instances, a second ICV, which is another one-way ICV, is placed within the first lateral, above a window that connects the second lateral to the first lateral, to control the flow from the second lateral. At Step708, the ICV causes a lift of the fluid received from a second lateral within the well when the ICV is open. In some example embodiments, the processor generates an instruction for actuating the ICV based on the dynamically determined pressure gradient. The processor transmits the instruction for actuating the ICV to a surface panel. The surface panel receives the instruction for actuating the ICV, and actuates (opens or chokes) the ICV based on the instruction. The ICV causes the lift of the fluid received from the second lateral within the well when the ICV is open as a result of the surface panel causing an opening of the ICV based on the instruction. Further details with respect to the operations of the method700are described below with respect toFIG.8. As shown inFIG.8, the method700may include Step802, according to some example embodiments. Step802may be performed after operation706, in which the ICV that is placed within the first lateral automatically controls the flow of the gas from the downhole natural gas source into the multilateral well based on the dynamically determined pressure gradient. At operation802, an isolation packer (e.g., the isolation packer612) that is placed within the first lateral and above the ICV causes the gas to flow through the ICV based on eliminating (e.g., precluding) behind-pipe flow through the first lateral. The isolation packer may be open-hole to allow its placement above the ICV. Open-hole packers eliminate behind-pipe flow and ensure that the ICVs are the only opening for fluid flow. In some example embodiments, the ICV is included in an ICV completion system, and an isolation packer is placed within the first lateral and above the ICV completion system. In various example embodiments, the isolation packer is included in the ICV completion system. In certain example embodiments, the ICV completion system further includes at least one of a pressure sensor to measure a pressure of the gas within the ICV completion system, a temperature sensor to measure a temperature of the gas within the ICV completion system, or a communication module to receive communications from the processor and to transmit communications to the processor. Example embodiments may be implemented on a computing system. Any combination of mobile, desktop, server, router, switch, embedded device, or other types of hardware may be used. For example, as shown inFIG.9A, the computing system900may include one or more computer processors902, non-persistent storage904(e.g., volatile memory, such as random access memory (RAM) or cache memory), persistent storage906(e.g., a hard disk, an optical drive such as a compact disk (CD) drive or digital versatile disk (DVD) drive, or a flash memory), a communication interface912(e.g., Bluetooth interface, infrared interface, network interface, or optical interface), and numerous other elements and functionalities. The computer processor(s)902may be an integrated circuit for processing instructions. For example, the computer processor(s)902may be one or more cores or micro-cores of a processor. The computing system900may also include one or more input devices910, such as a touchscreen, keyboard, mouse, microphone, touchpad, or electronic pen. The communication interface912may include an integrated circuit for connecting the computing system900to a network (not shown) (e.g., a local area network (LAN), a wide area network (WAN), such as the Internet, mobile network, or any other type of network) or to another device, such as another computing device. Further, the computing system900may include one or more output devices908, such as a screen (e.g., a liquid crystal display (LCD), a plasma display, touchscreen, cathode ray tube (CRT) monitor, or projector), a printer, external storage, or any other output device. One or more of the output devices may be the same or different from the input device(s). The input and output device(s) may be locally or remotely connected to the computer processor(s)902, non-persistent storage904, and persistent storage906. Many different types of computing systems exist, and the aforementioned input and output device(s) may take other forms. Software instructions in the form of computer readable program code to perform embodiments of the disclosure may be stored, in whole or in part, temporarily or permanently, on a non-transitory computer readable medium such as a CD, DVD, storage device, a diskette, a tape, flash memory, physical memory, or any other computer readable storage medium. Specifically, the software instructions may correspond to computer readable program code that when executed by a processor(s) is configured to perform one or more embodiments of the disclosure. The computing system900inFIG.9Amay be connected to or be a part of a network. For example, as shown inFIG.9B, the network916may include multiple nodes (e.g., node X918or node Y920). Each node may correspond to a computing system, such as the computing system shown inFIG.9B, or a group of nodes combined may correspond to the computing system shown inFIG.9B. By way of an example, embodiments of the disclosure may be implemented on a node of a distributed system that is connected to other nodes. By way of another example, embodiments of the disclosure may be implemented on a distributed computing system having multiple nodes, where each portion of the disclosure may be located on a different node within the distributed computing system. Further, one or more elements of the aforementioned computing system914may be located at a remote location and connected to the other elements over a network. Although not shown inFIG.9B, the node may correspond to a blade in a server chassis that is connected to other nodes via a backplane. By way of another example, the node may correspond to a server in a data center. By way of another example, the node may correspond to a computer processor or micro-core of a computer processor with shared memory or resources. The nodes (e.g., node X918or node Y920) in the network916may be configured to provide services for a client device922. For example, the nodes may be part of a cloud computing system. The nodes may include functionality to receive requests from the client device922and transmit responses to the client device922. The client device922may be a computing system, such as the computing system shown inFIG.9B. Further, the client device922may include or perform all or a portion of one or more embodiments of the disclosure. The computing system or group of computing systems described inFIGS.9A and9Bmay include functionality to perform a variety of operations disclosed herein. For example, the computing system(s) may perform communication between processes on the same or different systems. A variety of mechanisms, employing some form of active or passive communication, may facilitate the exchange of data between processes on the same device. Examples representative of these inter-process communications include, but are not limited to, the implementation of a file, a signal, a socket, a message queue, a pipeline, a semaphore, shared memory, message passing, and a memory-mapped file. Further details pertaining to a couple of these non-limiting examples are provided in subsequent paragraphs. Based on the client-server networking model, sockets may serve as interfaces or communication channel end-points enabling bidirectional data transfer between processes on the same device. Foremost, following the client-server networking model, a server process (e.g., a process that provides data) may create a first socket object. Next, the server process binds the first socket object, thereby associating the first socket object with a unique name or address. After creating and binding the first socket object, the server process then waits and listens for incoming connection requests from one or more client processes (e.g., processes that seek data). At this point, when a client process wishes to obtain data from a server process, the client process starts by creating a second socket object. The client process then proceeds to generate a connection request that includes at least the second socket object and the unique name or address associated with the first socket object. The client process then transmits the connection request to the server process. Depending on availability, the server process may accept the connection request, establishing a communication channel with the client process, or the server process, busy in handling other operations, may queue the connection request in a buffer until the server process is ready. An established connection informs the client process that communications may commence. In response, the client process may generate a data request specifying the data that the client process wishes to obtain. The data request is subsequently transmitted to the server process. Upon receiving the data request, the server process analyzes the request and gathers the requested data. Finally, the server process then generates a reply including at least the requested data and transmits the reply to the client process. The data may be transferred, more commonly, as datagrams or a stream of characters (e.g., bytes). Rather than or in addition to sharing data between processes, the computing system performing one or more embodiments of the disclosure may include functionality to receive data from a user. For example, in one or more embodiments, a user may submit data via a graphical user interface (GUI) on the user device. Data may be submitted via the graphical user interface by a user selecting one or more graphical user interface widgets or inserting text and other data into graphical user interface widgets using a touchpad, a keyboard, a mouse, or any other input device. In response to selecting a particular item, information regarding the particular item may be obtained from persistent or non-persistent storage by the computer processor. Upon selection of the item by the user, the contents of the obtained data regarding the particular item may be displayed on the user device in response to the selection by the user. By way of another example, a request to obtain data regarding the particular item may be sent to a server operatively connected to the user device through a network. For example, the user may select a uniform resource locator (URL) link within a web client of the user device, thereby initiating a Hypertext Transfer Protocol (HTTP) or other protocol request being sent to the network host associated with the URL. In response to the request, the server may extract the data regarding the particular selected item and send the data to the device that initiated the request. Once the user device has received the data regarding the particular item, the contents of the received data regarding the particular item may be displayed on the user device in response to the selection by the user. Further to the above example, the data received from the server after selecting the URL link may provide a web page in Hyper Text Markup Language (HTML) that may be rendered by the web client and displayed on the user device. The computing system inFIG.9Bmay implement or be connected to a data repository. For example, one type of data repository is a database. A database is a collection of information configured for ease of data retrieval, modification, re-organization, and deletion. Database management system (DBMS) is a software application that provides an interface for users to define, create, query, update, or administer databases. The user, or software application, may submit a statement or query into the DBMS. Then the DBMS interprets the statement. The statement may be a select statement to request information, update statement, create statement, delete statement, etc. Moreover, the statement may include parameters that specify data, or data container (database, table, record, column, view, etc.), identifier(s), conditions (comparison operators), functions (e.g., join, full join, count, or average), sort (e.g., ascending or descending), or others. The DBMS may execute the statement. For example, the DBMS may access a memory buffer, a reference or index a file for read, write, deletion, or any combination thereof, for responding to the statement. The DBMS may load the data from persistent or non-persistent storage and perform computations to respond to the query. The DBMS may return the result(s) to the user or software application. The computing system ofFIG.9Bmay include functionality to present raw or processed data, such as results of comparisons and other processing. For example, presenting data may be accomplished through various presenting methods. Specifically, data may be presented through a user interface provided by a computing device. The user interface may include a GUI that displays information on a display device, such as a computer monitor or a touchscreen on a handheld computer device. The GUI may include various GUI widgets that organize what data is shown as well as how data is presented to a user. Furthermore, the GUI may present data directly to the user, for example, data presented as actual data values through text, or rendered by the computing device into a visual representation of the data, such as through visualizing a data model. For example, a GUI may first obtain a notification from a software application requesting that a particular data object be presented within the GUI. Next, the GUI may determine a data object type associated with the particular data object, for example, by obtaining data from a data attribute within the data object that identifies the data object type. Then, the GUI may determine any rules designated for displaying that data object type, for example, rules specified by a software framework for a data object class or according to any local parameters defined by the GUI for presenting that data object type. Finally, the GUI may obtain data values from the particular data object and render a visual representation of the data values within a display device according to the designated rules for that data object type. The previous description of functions presents only a few examples of functions performed by the computing system ofFIG.9Aand the nodes or client device inFIG.9B. Other functions may be performed using one or more embodiments of the disclosure. While the disclosure has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the disclosure as disclosed. Accordingly, the scope of the disclosure should be limited only by the attached claims. Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. § 112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function. | 50,805 |
11859474 | Like reference symbols in the various drawings indicate like elements. DETAILED DESCRIPTION This disclosure describes an artificial lift system that includes a downhole-type rotating machine, such as a compressor, blower, pump, or generator. Use of such artificial lift systems can increase production from wells. In some implementations, the bearing lubrication system of the artificial lift system is isolated from the production fluid via sealed chambers or zones, typically flooded with the lubrication fluid and pressure compensated to the downhole environment to minimize leakage and contamination with the production fluid. While this approach offers use in low speed applications, higher speed applications suffer from the high windage losses from this flooded approach. The artificial lift systems described herein can be more reliable than comparable artificial lift systems with the elimination of a flooded electric machine located downhole. The artificial lift systems described herein also offer improved performance by being able to achieve higher operating speeds, all while using conventional lubricated bearing systems. The downhole-type rotating machine is provided lubrication, at least partially, by an adjustable topside pressure source that is renewed/refilled as needed, where lubrication used in the device is ultimately recovered in the production flow that comes to the topside facility. The modular characteristic of the artificial systems described herein allows for variability in design and customization to cater to a wide range of operating conditions and applications, including wells producing liquid, gas, and combinations of both. FIG.1depicts an example well system100constructed in accordance with the concepts herein. The well system100includes a well102having a wellbore104that extends from the terranean surface106through the earth108to one or more subterranean zones of interest110(one shown). The well system100enables access to the subterranean zones of interest110to allow recovery, i.e., production, of fluids to the terranean surface106and, in certain instances, additionally or alternatively allows fluids to be placed in the earth108. In certain instances, the subterranean zone of interest110is a formation within the Earth defining a reservoir, but in other instances, the subterranean zone of interest110can be multiple formations or a portion of a formation. For the sake of simplicity, the well102is shown as a vertical well with a vertical wellbore104, but in other instances, the well102could be a deviated well with the wellbore104deviated from vertical (e.g., horizontal or slanted) and/or the wellbore104could be one of the multiple bores of a multilateral well (i.e., a well having multiple lateral wells branching off another well or wells). In certain instances, the well system100is used in producing hydrocarbon production fluid from the subterranean zones of interest110to the terranean surface106. The well may produce only dry gas, liquid hydrocarbons, and/or water. In certain instances, the production from the well102can be multiphase in any ratio. The well102can produce mostly or entirely liquid at certain times and mostly or entirely gas at other times. For example, in certain types of wells, it is common to produce water for a period of time to gain access to the gas in the subterranean zone. The concepts herein, though, are not limited in applicability to gas wells or even production wells, and could be used in wells for producing liquid resources such as oil, water, or other liquid resources, and/or could be used in injection wells, disposal wells, or other types of wells used in placing fluids into the Earth. The wellbore104is typically, although not necessarily, cylindrical. All or a portion of the wellbore104is lined with a tubing, i.e., casing112. The casing112connects with a wellhead118at the terranean surface106and extends downhole into the wellbore104. The casing112operates to isolate the bore of the well102, defined in the cased portion of the well102by the inner bore116of the casing112, from the surrounding earth108. The casing112can be formed of a single continuous tubing or multiple lengths of tubing joined (e.g., threaded and/or otherwise) end-to-end. InFIG.1, the casing112is perforated (i.e., having perforations114) in the subterranean zone of interest110to allow fluid communication between the subterranean zone of interest110and the inner bore116of the casing112. In other instances, the casing112is omitted or ceases in the region of the subterranean zone of interest110. This portion of the wellbore104without casing is often referred to as “open hole.” The wellhead118defines an attachment point for other equipment of the well system100to be attached to the well102. For example,FIG.1shows well102being produced with a Christmas tree120attached to the wellhead118. The Christmas tree120includes valves used to regulate flow into or out of the well102. FIG.1shows a surface pump/compressor122residing on the terranean surface106and fluidly coupled to the well102through the Christmas tree120. The surface pump/compressor122can include a variable speed or fixed speed pump/compressor. The well system100also includes a downhole-type artificial lift system124residing in the wellbore104, for example, at a depth that is at or nearer to subterranean zone of interest110than the terranean surface106. The surface pump/compressor122operates to draw down the pressure inside the well102at the terranean surface106to facilitate production of fluids to the terranean surface106and out of the well102. The downhole-type artificial lift system124, being of a type configured in size and robust construction for installation within a well102, assists by creating an additional pressure differential within the well102. In particular, casing112is commercially produced in a number of common sizes specified by the American Petroleum Institute (the “API”), including 4½, 5, 5½, 6, 6⅝, 7, 7⅝, 16/8, 9⅝, 10¾, 11¾, 13⅜, 16, 18⅝ and 20 inches, and the API specifies internal diameters for each casing size. The downhole-type artificial lift system124can be configured to fit in and, (as discussed in more detail below) in certain instances, seal to the inner diameter of one of the specified API casing sizes. Of course, the downhole-type artificial lift system124can be made to fit in and, in certain instances, seal to other sizes of casing or tubing or otherwise seal to the wall of the wellbore104. Additionally, as a downhole-type artificial lift system124or any other downhole system configuration such as a pump, compressor, or multi-phase fluid flow aid that can be envisioned, the construction of its components is configured to withstand the impacts, scraping, and other physical challenges that the downhole-type artificial lift system124will encounter while being passed hundreds of feet/meters or even multiple miles/kilometers into and out of the wellbore104. For example, the downhole-type artificial lift system124can, in certain instances, be disposed in the wellbore104at a depth of 15,000 feet (4,572 meters) or more. Beyond just a rugged exterior, this encompasses having certain portions of any electronics or components sensitive to the downhole environment be ruggedized to be shock resistant and remain fluid tight during such physical challenges and during operation. Additionally, the downhole-type artificial lift system124is configured to withstand and operate for extended periods of time (e.g., multiple weeks, months, or years) at the pressures and temperatures experienced in the wellbore104, temperatures which, in certain instances, can exceed 400° F./205° C. and pressures over 10,000 pounds per square inch, and while submerged in the well fluids (gas, water, or oil as examples). Finally, as a downhole-type artificial lift system124, the downhole-type artificial lift system124can be configured to interface with one or more of the common deployment systems, such as jointed tubing (i.e., lengths of tubing joined end-to-end, threaded, and/or otherwise), a sucker rod, coiled tubing (i.e., not-jointed tubing, but rather a continuous, unbroken and flexible tubing formed as a single piece of material), or wireline with an electrical conductor (i.e., a monofilament or multifilament wire rope with one or more electrical conductors, sometimes called e-line) and thus have a corresponding connector (e.g., coupling218discussed below, which can be a jointed tubing connector, coiled tubing connector, or wireline connector). InFIG.1, the downhole-type artificial lift system124is shown deployed on production tubing128. A seal system126integrated or provided separately with a downhole system, as shown with the downhole-type artificial lift system124, divides the well102into an uphole zone130above the seal system126and a downhole zone132below the seal system126.FIG.1shows the downhole-type artificial lift system124positioned in the open volume of the inner bore116of the casing112, and not within or a part of another string of tubing in the well102. The wall of the wellbore104includes the interior wall of the casing112in portions of the wellbore104having the casing112, and includes the open-hole wellbore wall in uncased portions of the wellbore104. Thus, the seal system126is configured to seal against the wall of the wellbore104, for example, against the interior wall of the casing112in the cased portions of the wellbore104or against the interior wall of the wellbore104in the uncased, open-hole portions of the wellbore104. In certain instances, the seal system126can form a gas and liquid tight seal at the pressure differential that the downhole-type artificial lift system124creates in the well102. In some instances, the seal system126of the downhole-type artificial lift system124seals against the interior wall of the casing112or the open-hole portion of the wellbore104. For example, the seal system126can be configured to at least partially seal against an interior wall of the wellbore104to separate (completely or substantially) a pressure in the wellbore104downhole of the seal system126of the downhole-type artificial lift system124from a pressure in the wellbore104uphole of the seal system126of the downhole-type artificial lift system124. AlthoughFIG.1includes both the surface pump/compressor122and the downhole-type artificial lift system124, in other instances, the surface pump/compressor122can be omitted and the downhole-type artificial lift system124can provide the entire pressure boost in the well102. While illustrated with the seal system126, such a seal system can be eliminated in some instances, for example, when a packer and production tubing are used with the downhole-type artificial lift system124. In some implementations, the downhole-type artificial lift system124can be implemented to alter characteristics of a wellbore by a mechanical intervention at the source. Alternatively or in addition to any of the other implementations described in this disclosure, the downhole-type artificial lift system124can be implemented as a high flow, low pressure rotary device for gas flow in sub-atmospheric wells. Alternatively or in addition to any of the other implementations described in this disclosure, the downhole-type artificial lift system124can be implemented as a high pressure, low flow rotary device for gas flow in sub-atmospheric wells. Alternatively or in addition to any of the other implementations described in this disclosure, the downhole-type artificial lift system124can be implemented as a high flow, low pressure rotary device for gas flow in high pressure wells, that is, wells with a pressure higher than atmospheric pressure. Alternatively, or in addition to any of the other implementations described in this disclosure, the downhole-type artificial lift system124can be implemented as a high pressure, low flow rotary device for gas flow in high-pressure wells. Alternatively, or in addition to any of the other implementations described in this disclosure, the downhole-type artificial lift system124can be implemented in a direct well-casing deployment for production through the wellbore. While the downhole-type artificial lift system124is described in detail as an example implementation of the downhole system, alternative implementations of the downhole system as a pump, compressor, or multiphase combination of these can be utilized in the wellbore to effect increased well production. The downhole system, as shown as the downhole-type artificial lift system124, locally alters the pressure, temperature, and/or flow rate conditions of the fluid in the wellbore104proximate the downhole-type artificial lift system124(e.g., at the base of the wellbore104). In certain instances, the alteration performed by the downhole-type artificial lift system124can optimize, or help in optimizing, fluid flow through the wellbore104. As described above, the downhole-type artificial lift system124creates a pressure differential within the well102, for example, particularly within the wellbore104the downhole-type artificial lift system124resides in. In some instances, a pressure at the base of the wellbore104is a low pressure (e.g., sub-atmospheric, insufficient to overcome the static head and friction losses of the well, or insufficient for the desired flowrate at the Christmas tree120), so unassisted fluid flow in the wellbore can be slow or stagnant. In these and other instances, the downhole-type artificial lift system124introduced into the wellbore104adjacent the perforations114can reduce the pressure in the wellbore104near the perforations114to induce greater fluid flow from the subterranean zone of interest110, increase a temperature of the fluid entering the downhole-type artificial lift system124to reduce condensation from limiting production, and increase a pressure in the wellbore104uphole of the downhole-type artificial lift system124to increase fluid flow to the terranean surface106. The downhole system, as shown as the downhole-type artificial lift system124, moves the fluid at a first pressure downhole of the downhole-type artificial lift system124to a second, higher pressure uphole of the downhole-type artificial lift system124. The downhole-type artificial lift system124can operate at and maintain a pressure ratio across the downhole-type artificial lift system124between the second, higher uphole pressure and the first, downhole pressure in the wellbore. The pressure ratio of the second pressure to the first pressure can also vary, for example, based on an operating speed of the downhole-type artificial lift system124, as described in more detail below. In some instances, the pressure ratio across the downhole-type artificial lift system124is less than 2:1, where a pressure of the fluid uphole of the downhole-type artificial lift system124(i.e., the second, higher pressure) is at or below twice the pressure of the fluid downhole of the downhole-type artificial lift system124(i.e., the first pressure). For example, the pressure ratio across the downhole-type artificial lift system124can be about 1.125:1, 1.5:1, 1.75:1, 2:1, or another pressure ratio between 1:1 and 2:1. In certain instances, the downhole-type artificial lift system124is configured to operate at a pressure ratio of greater than 2:1. The downhole system, as shown as the downhole-type artificial lift system124, can operate in a variety of downhole conditions of the wellbore104. For example, the initial pressure within the wellbore104can vary based on the type of well102, depth of the well102, production flow from the perforations114into the wellbore104, and/or other factors. In some examples, the pressure in the wellbore104proximate a bottomhole location is sub-atmospheric, where the pressure in the wellbore104is at or below about 14.7 pounds per square inch absolute (psia), or about 101.3 kiloPascal (kPa). The downhole-type artificial lift system124can operate in sub-atmospheric wellbore pressures, for example, at wellbore pressure between 2 psia (13.8 kPa) and 14.7 psia (101.3 kPa). In some examples, the pressure in the wellbore104proximate a bottomhole location is much higher than atmospheric pressure, where the pressure in the wellbore104is above about 14.7 pounds per square inch absolute (psia), or about 101.3 kiloPascal (kPa). The downhole-type artificial lift system124can operate in above atmospheric wellbore pressures, for example, at wellbore pressure between 14.7 psia (101.3 kPa) and 15,000 psia (103,421 kPa). A controller150for a downhole system, shown as the downhole-type artificial lift system124, is, in some implementations, located topside to maximize reliability and serviceability. Details about the controller150are described later within this disclosure. The controller150, in some implementations, receives signals from well instrumentation (pressure, flow, temperature), the topside motor VSD (speed, power, torque), the topside oil supply system (lubrication flow, pressure, temperature), and any sensor and/or sensor electronics within the downhole-type artificial lift system124, and uses this for input as part of its operation and control algorithm. This algorithm output includes a current command to regulate rotor speed and lubrication rates within the downhole-type artificial lift system124(details are explained in greater detail later within the disclosure). This loop typically happens very fast, on the order of 1,000-20,000 times a second depending on the system control requirements. This control system is also capable of determining the bearing lubrication requirements based on speed, power, fluid flow, and fluid pressures in the well. Analog circuit based controllers can also perform this function. Having this controller150topside allows for easy communication, service, and improved up-time for the system, as any issues can be resolved immediately via local or remote support. Downhole electronics are also an option either proximate to the device or at a location more thermally suitable. In a downhole implementation, the electronics are packaged to isolate them from direct contact with the downhole environment. Downhole electronics, in certain instances, offer better control since they do not suffer with long cable delay and response issues. Lubrication is provided with a topside pressure source154. The topside pressure source154can include a pump, a flow regulator, a pressure regulator, a pressurized vessel, valving, and any other equipment to provide lubrication to the downhole-type artificial lift system124. The topside pressure source154is fluidically connected to the downhole-type artificial lift system124by a main lubrication line152. In addition to standard lubrication, the topside pressure source154can provide well treatment chemicals to the downhole-type artificial lift system124. Such chemicals can include corrosion inhibitors, defoamers, such as alkoxylated alcohol, paraffin inhibitors, such as xylene, toluene and benzene, wetting agents, such as certain soaps, and hydrate inhibitors, such as methanol or monoethylene glycol (MEG). For especially corrosive chemicals, different metallurgy or coatings could be utilized for bearing systems. These could include nickel and chromium based surface applications, as well as nickel based or super alloys. In addition, ceramic roller elements could be selected for use in more aggressive fluid. The bearing cage material would be selected with the chemical constituents in mind whether they be metallic or thermoplastic. More details on the lubrication system are described throughout this disclosure. An example downhole system, shown as the downhole-type artificial lift system124, is depicted schematically inFIG.1. In the context of this disclosure, an uphole end or direction is an end nearer or moving in a direction towards the terranean surface106. A downhole end or direction is an end nearer or moving in a direction away from the terranean surface106. In some implementations, a coupling is positioned at an uphole-end of the downhole-type artificial lift system124. The coupling can be of a type used for a wireline connection, a tubing connection, or any other connection configured to support the weight of all or part of the downhole-type artificial lift system124. The coupling, in certain instances, can include a standard attachment method to attach the downhole-type artificial lift system124to a support system. For example, a threaded interface can be used for sucker rod, or a set of bolts can be used to attach two flanges together for production tubing. FIG.2illustrates an example lubrication system200for an example well tool202. The well tool202can be used as the downhole-type artificial lift system124previously described. The well tool202includes an electric machine204configured to be positioned within the wellbore104(not shown). The electric machine204has a housing206fluidically isolating the electric machine204from the wellbore104. Within the housing206is a first lubrication circuit208that includes a lubrication reservoir210. The lubrication reservoir210is fluidically connected to, and is configured to provide lubrication to, a first set of bearings212within the electric machine204. The first set of bearings212carry an electric rotor205and are supported by the electric stator207of the electric machine204. At an uphole end of the well tool202is a fluid end214. The fluid end214includes a fluid rotor215and a fluid stator217. The fluid rotor215is configured to act upon or be acted upon by the fluid within the wellbore104. That is, the fluid rotor215can move or can be moved by fluid within the wellbore104. In general, such movement is usually rotational movement, but other movements can include other movements, such as a reciprocating movement. The fluid rotor215can include a pump rotor, an impeller, a turbine, a screw, a reciprocating rod, or any other fluid moving component. The fluid stator217can include stator vanes, diffusers, or any other static component used to direct fluid through the fluid end214. The fluid end214includes a second set of bearings216carrying the fluid rotor215and supported by the fluid stator217. In between the electric machine204and the fluid end214is a magnetic coupling218. The magnetic coupling218couples the fluid rotor215and a rotor of the electric machine204to rotate in unison. The magnetic coupling218includes a first coupling rotor and a second coupling rotor magnetically coupled together. Between the first coupling rotor and the second coupling rotor is a can220. The can220fluidically isolates the electric machine204from the remainder of the wellbore104and components of the well tool202, including the fluid end214. The first coupling rotor and second coupling rotor can have a barrel shape with a radial gap arrangement, rotating plates with an axial gap, or a combination of the two. Regardless of the arrangement, the first coupling rotor and the second coupling rotor are separated from one another and fluidically isolated from one another by the can220. That is, the first coupling rotor is attached or connected to the fluid rotor215and is exposed to the wellbore fluid while the second coupling rotor is attached or connected to the electric rotor205and is completely isolated from the wellbore fluid. The first coupling rotor can be rotationally supported on the fluid rotor215bearings or supported on a separate set of bearings, and the second coupling rotor can be rotationally supported on the electric rotor205bearings or supported on a separate set of bearings. Lubricant is used by both the first set of bearings212within the electric machine204, and the second set of bearings216within the fluid end214. As illustrated, lubrication within the electric machine204is completely self-contained and is primarily stored within the lubrication reservoir210. The lubrication reservoir210includes a downhole lubrication pump222that is able to circulate the lubricant through the first set of bearings212within the electric machine204and recover back lubricant into the lubrication reservoir210. These components make-up a first lubrication circuit208. This first lubrication circuit208is hermetically isolated from the wellbore104. The second set of bearings216within the fluid end214may also require lubrication. As illustrated, lubrication for the second set of bearings216within the fluid end214is provided by the topside pressure source154. The topside pressure source154flows the lubricant down a lubrication line152, the lubrication provided by the topside pressure source154is then directed to the second set of bearings216within the fluid end214. Once lubricant flows through the second set of bearings216within the fluid end214, any excess lubricant flows into the process fluid. The topside pressure source154can flow the lubricant down a lubrication line152and through an isolated part of the lubrication reservoir210. This isolated part of the lubrication reservoir210can be used to drive a hydraulic motor224. That is, the lubrication flow rotates a small turbine within the hydraulic motor224. This small turbine, in turn, rotates the downhole lubrication pump222within the lubrication reservoir210. After driving the downhole lubrication pump222within the lubrication reservoir210, the lubrication provided by the topside pressure source154is then directed to the second set of bearings216within the fluid end214. Once lubricant flows through the second set of bearings216within the fluid end214, any excess lubricant flows into the process fluid. While primarily described in the context of bearings within the fluid end214and within the electric machine204, additional bearings, for example, within the magnetic coupling218, can be lubricated by any of the lubrication systems described herein. For example, the portion of the magnetic coupling218that is isolated with the electric machine204is lubricated by the first lubrication circuit208while the portion of the magnetic coupling218coupled to the fluid end214is lubricated by the second lubrication circuit226. In some implementations, the use of the magnetic coupling218allows for easy change-out of the fluid end214. In such instances, the fluid end214and the fluid end portion of the magnetic coupling218can be removed while the electric machine204and the electric motor portion of the magnetic coupling218remain within the wellbore104. Such flexibility allows the fluid end214to be changed out or swapped to be matched with performance characteristics desired for the current production rate and composition of fluid within the wellbore104. In addition, since the electric machine204is isolated from the wellbore104, the electric machine204will have a far greater mean-time-between-failures or mean-time-between-overhauls when compared with the fluid end214. To facilitate this easy removal and reinstall, lubrication lines may be preinstalled or formed within the housing206such that whenever the components are reconnected the lubrication lines and lubrication circuits (224and226) are completed. In operation, the first lubricant is flowed by the first lubrication circuit208to a first set of bearings212within the electric machine204of the downhole tool202. The electric machine204includes an electric rotor205and an electric stator207. The first set of bearings212supports the electric rotor205within the electric stator207. The electric machine204and the first set of bearings212are isolated from a wellbore104by a pressure-sealed housing206. A second lubricant is flowed by the second lubrication circuit226to the second set of bearings216within the fluid end214. The fluid end214includes a fluid rotor215and a fluid stator217. The second set of bearings216supports the fluid rotor215within the fluid stator217. The second set of bearings216is exposed to the wellbore104. That is, the second set of bearings216is fluidically exposed to wellbore fluids during operation. In some implementations, the first lubricant is received by the lubrication reservoir210prior to flowing the first lubricant. For example, the lubrication reservoir210can be pre-filled before the well tool202is installed within a wellbore. In some implementations, flowing the first lubricant includes flowing the second lubricant from a topside pressure source154, located at the terranean surface106, through a hydraulic motor224driven by the flowing second lubricant. The downhole lubrication pump222can then be driven by the hydraulic motor224. The first lubricant is driven or flowed at least partly by the downhole lubrication pump222. The second lubricant is flowed from the hydraulic motor224to the second set of bearings216. FIG.3illustrates an example lubrication system300for an example well tool302. The well tool302can be used as the downhole-type artificial lift system124previously described. Lubrication system300is substantially similar to the lubrication system200previously described with the exception of any differences described herein. Similar to the implementation illustrated inFIG.2, the second set of bearings216within the fluid end214are lubricated by lubricant supplied from a topside pressure source154. The first lubrication circuit208within the electric machine204is similarly isolated. In this implementation, an electric motor324, separate from the electric machine204, is used to drive the downhole lubrication pump222and circulate the lubricant within the first lubrication circuit208. In some implementations, the electric motor324has power supplied from the topside facility by a power cable352. Alternatively, or in addition, the electric motor324has power supplied from the electric machine204itself, directly, taking input power for the electric machine204input from the surface motor drive and using to drive the electric motor324. A power conditioning circuit could be used, which could include electronics, to control the input to the electric machine324to provide a constant power, torque, current, voltage or other form or combination for control of lubricate flow. Alternatively, or in addition, an electric generator connected to and driven by the electric machine204shaft could be used, whose output used to drive the electric motor324. A power conditioning circuit could be used, which could include electronics, to control the input to the electric machine324to provide a constant power, torque, current, voltage or other form or combination for control of lubricate flow. Alternatively, or in addition, other power sources can be used for the electric motor324, for example, batteries. In operation, pumping the first lubricant includes receiving electricity by the electric motor324. As illustrated, the electric motor324is within the well tool302. More specifically, the electric motor324is within the sealed housing206; however, the electric motor324can be located outside of the sealed housing206so long as the seal is maintained. For example, a second magnetic coupling or dynamic seal can be used, or the motor and pump can be located in a separate sealed assembly with tubes or other convenes items used to bring lubricate to the pump and carry pumped lubricate to the bearings. Regardless, the downhole lubrication pump222is driven by the electric motor324. FIG.4illustrates an example lubrication system400for an example well tool402. The well tool402can be used in place of the downhole-type artificial lift system124previously described. The lubrication system400can be used in lieu of any of the previously described lubrication systems. Lubrication system400is substantially similar to the lubrication system300previously described with the exception of any differences described herein. In the illustrated implementation, the downhole lubrication pump222within the lubrication reservoir210is driven directly by the electric machine204. In some implementations, the electric machine204may spin at too high of a rate for the downhole lubrication pump222to operate efficiently. In such implementations, a gearbox or others form of speed reducer404can be used between the electric machine204and the downhole lubrication pump222. For example, rotary magnetic gears or fluid couplings can be used. FIG.5illustrates an example lubrication system500for an example well tool502. The well tool502can be used in place of the downhole-type artificial lift system124previously described. The lubrication system500can be used in lieu of any of the previously described lubrication systems. Lubrication system500is substantially similar to the lubrication system400previously described with the exception of any differences described herein. In the illustrated implementation, the second lubrication circuit226, lubricating the second set of bearings216within the fluid end214, is fed by the topside pressure source154. Similarly, the first set of bearings212, within the electric machine204and part of the first lubrication circuit208, is also supplied by the topside pressure source154. In some implementations, a separate topside pump can be used. In this implementation, the lubricant is flowed by the topside pressure source154into the isolated electric machine204, and then into the downhole lubrication reservoir510. The downhole lubrication reservoir510is equipped with a pressure relief valve512. The pressure relief valve512is set to release contents of the downhole lubrication reservoir510when an internal pressure of the downhole lubrication reservoir510exceeds a pressure within the wellbore104. In this arrangement, the lubricant released by the pressure relief valve512is then swept into the working fluid through the fluid end214towards the Christmas tree120. In operation, the first lubricant is received from the first lubrication circuit208by a downhole lubrication reservoir510within the downhole tool. A pressure within the downhole lubrication reservoir510is increased as the lubricate column height increases such that the pressure within the downhole lubrication reservoir510is greater than a pressure within the wellbore104. The lubricant is released, by a pressure relief valve512, to the wellbore104in response to the pressure within the downhole lubrication reservoir510being greater than the pressure of the wellbore104. The pressure relief valve512to the wellbore104, reacting to the higher pressure in the downhole lubrication reservoir510, prevents the well fluids from entering the downhole lubrication reservoir510. A pressure within the downhole lubrication reservoir510is reduced in response to releasing the lubricant to the wellbore104. FIG.6is a block diagram of the controller150. As shown inFIG.6, the controller150can include one or more processors602and non-transitory memory604containing instructions to facilitate sending and receiving signals through an input/output (I/O) interface606. The controller can communicate with any aspect of the downhole-type artificial lift system124, or topside components, for example, the topside pressure source154. In some implementations, the controller150can be entirely located at the surface outside the wellbore104. In some implementations, the controller150can be located within the wellbore104. In some implementations, the controller can be a distributed controller; for example, a portion of the controller150can be located within the wellbore104, while another portion of the controller150can be located at the surface outside the wellbore104. In some implementations, the controller150can be only or in part an analog circuit based control. The present disclosure is also directed to a method of monitoring, controlling, and using the downhole-type artificial lift system124. To monitor and control the downhole-type artificial lift system124, the controller150is used in conjunction with sensors (e.g., velocity sensors, transducers, thermocouples, flow sensors, fluid composition sensors) to measure parameters of the production fluid and the downhole-type artificial lift system124at various positions within the wellbore104. Input and output signals, including the data from the sensors, controlled and monitored by the controller150, can be logged continuously by the controller150and stored in a memory604coupled to the controller150. The input and output signals can be logged at any rate desirable by the operator of the downhole-type artificial lift system124. The controller150can also be used to operate and control any motors, bearings, valves, or flow control devices disclosed herein. For example, the controller150can be used to control the topside pressure source154. Furthermore, the controller150can be used with the downhole-type artificial lift system124to operate the downhole-type artificial lift system124in any matter described herein. In some implementations, the controller150can be used to operate other devices, such as a topside pump, compressor, or separator in conjunction with the downhole-type artificial lift system124. The memory604can store programming instructions for execution by the one or more processors602. For example, the processors can execute programming instructions to measure and/or monitor a parameter detected by various sensors. The controller150interprets the signal from sensors and directs the topside pressure source154to provide lubrication to the bearings at a specified rate. In another example, the controller150can take a measured parameter of the downhole-type artificial lift system124and change a rate of lubrication to the bearings in response to the measured parameter. Alternatively, or in addition, the one or more processors602can execute programing instructions to determine future well-flow characteristics based on a flow assurance model and control a speed of the rotor based on the future well-flow characteristics. A number of implementations of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other implementations are within the scope of the following claims. | 38,195 |
11859475 | DETAILED DESCRIPTION Certain aspects and examples of the present disclosure relate to a seal bag that includes multiple layers and that can be used in a seal for an electric submersible pump. The multiple layers can include an inner layer and an outer layer. In case of a tear in the seal, the inner layer can swell to seal the tear against an outer housing of the seal and effectively self-heal the tear. For example, the inner layer may be exposed to motor oil in a chamber defined by the seal and the motor oil may be for an electric motor of the electric submersible pump. A tear may allow water or other polar substances into the chamber. A polar substance, of which water is an example, can be a covalently bonded substance that contains partially positive and negative charges. In response to contact with the water or other polar substance, the inner layer can expand, such as by swelling, against the outer layer and the outer housing to seal the tear. The seal bag can provide a barrier to protect the electric motor and motor oil from contamination by the wellbore fluid. A tear may develop in the seal bag downhole that can result in wellbore fluid entering the chamber holding the motor oil. The seal bag may have the ability to self-heal when a tear develops in the seal bag. The ability to self-heal the tear can result in an increased functional life of the electric submersible pump and prevent tears from impeding the electric submersible pump from performing downhole operations. For example, wellbore fluid that contaminates motor oil within the electric motor and seal of an electric submersible pump can cause the motor oil to degrade and can cause the electric submersible pump to fail due to electrical failure or improper bearing operation. A seal bag that fails, such as by having a tear, can provide a path for wellbore fluid ingress. An elastomer seal bag can be used that has multiple plies or layers as a positive barrier within the seal. In one example, an outer layer is resistant to water, other polar substances, and hydrocarbons in wellbore fluid. And, an inner layer can include a polymer that can swell in response to contact with water and polar substances. The seal bag can provide a self-healing capability to the elastomer seal bag and can increase resistance to wellbore fluid infiltrating the electric submersible pump due to a tear in the elastomer seal. In an example, an elastomer seal bag can include multiple layers or plies and can be installed in a seal. The layers can include an outer layer that may be resistant to polar fluids and hydrocarbons found in wellbore fluid and can include an inner layer that may be a water-sensitive or polar-substance sensitive polymer that can swell. The seal can provide a positive barrier between wellbore fluid and oil contained within the seal. When the integrity of the outer layer of the elastomer seal bag is compromised, contact between the inner layer of the bag and water or other polar substance in the wellbore fluid can cause the polymer of the inner layer to swell to completely or partially seal the tear and prevent or slow the ingress of wellbore fluid into the seal. The self-healing quality of the elastomer seal bag can reduce the contamination of the oil contained within the seal. Using a multi-ply elastomer seal bag according to some examples can increase the resiliency of the seal section and can increase the electric submersible pump run-life. For example, when the integrity of the bag is compromised and the inner layer contacts wellbore fluid, the polymer material of the inner layer can swell as a result of the reaction to the wellbore fluid and can seal the tear in the seal bag. In some examples, a seal bag includes layers in addition to the outer layer and the inner layer. For example, the seal bag may include an additional layer between the inner layer and outer layer that may provide stiffness, permeability resistance, or other beneficial effects to the characteristics of the elastomer bag. Or, the middle layer may be considered to be a first inner layer that is made from a material that swells in response to contact with polar substances. In that example, the inner layer may be considered to be a second inner layer that may be made from a material that swells in response to contact with polar substances or from a different material that does not swell. The first inner layer can be a layer to provide self-healing in case of a tear. In addition or alternatively, a seal bag may have an outer layer with a slick or anti-stick surface that can promote movement of the seal bag along an inner surface of the seal housing and that may prevent friction coupling that can result in sticking and bunching of the bag that can lead to the tearing of the seal bag. Illustrative examples are given to introduce the reader to the general subject matter discussed herein and are not intended to limit the scope of the disclosed concepts. The following sections describe various additional features and examples with reference to the drawings in which like numerals indicate like elements, and directional descriptions are used to describe the illustrative aspects, but, like the illustrative aspects, should not be used to limit the present disclosure. FIG.1is a schematic of a wellbore105in which an electric submersible pump100, with a seal135that includes a bag, is positioned to communicate with surface equipment according to one example of the present disclosure. The wellbore105can be in a subterranean environment110and the electric submersible pump100may provide artificial lift to wellbore fluid by moving wellbore fluid from a position downhole to a surface165through a wellhead160. Artificial lift can be employed during the production phase of a hydrocarbon well after subterranean pressures have abated and a free-flow stage of the well has ended. The electric submersible pump100in the wellbore105can provide artificial lift to maintain the production rate from the wellbore105. The electric submersible pump100can have an electric motor120coupled to a pump145by a shaft to provide mechanical power to the pump145from the electric motor120. The pump145may have an intake140and a discharge155. The intake140can allow the pump145to draw in wellbore fluid and direct the wellbore fluid toward the surface165through the discharge155. The electric motor120may be electrically coupled to a variable speed controller130by a cable125. The variable speed controller130can provide both power and control signals to the electric motor120through the cable125. The variable speed controller130and the wellhead160may be positioned above the surface165. Between the pump145and the electric motor120is at least one seal135that can contain at least one seal bag positioned inside the seal135. The seal135can transfer torque to the pump145from the electric motor120. The seal135can prevent wellbore fluid from contaminating motor oil for the electric motor120through isolation, equalization, and expansion. The seal135may also prevent pump-shaft thrust from impacting motor performance through force absorption. The seal135and the seal bag can isolate the electric motor120from wellbore fluid that can otherwise cause electrical and mechanical faults of the electric motor120. Seal bags can be positioned in the seal135in one or more orientations. An example of an orientation is a series installation in which two or more seal bags can be positioned independently and can provide redundant isolation of the electric motor120. Another example of an orientation is a parallel installation in which two or more bags may be coupled together. The parallel installation can allow greater expansion of the motor oil given certain conditions in the wellbore105. And, a parallel installation can reduce the redundant isolation of the electric motor120. In either orientation, the seal bag can include multiple layers that can self-heal a tear in the seal135in the downhole environment. FIG.2is a partial cross-sectional schematic of a seal135that can be installed in an electric submersible pump and that includes seal bags216-220, each with multiple layers according to one example of the present disclosure. The seal135is depicted as having three sections defined between mechanical seals208-214and including seal bags216-220. Each of the seal bags216-220is positioned within an outer housing202. Although three seal bags216-220are shown inFIG.2, a seal according to other examples can have any number of seal bags, including one bag, two bags, or more than three bags. The seal sections can each include an interdigitated path, such as interdigitated path222. An interdigitated path may also be referred to as a labyrinth chamber. The interdigitated path222may be located in the seal bag220. In operation, the interdigitated path222may be filled with motor oil for an electric motor of an electric submersible pump. In the case of a tear, wellbore fluid may enter the seal135and displace the motor oil until the pressure between the two equalizes. The interdigitated path222can control the flow of wellbore fluid within the seal135for the purpose of limiting contamination of the motor oil with the wellbore fluid. The seal135also includes a guide tube204in which is positioned a shaft206. The shaft206can couple an electric motor to a pump of the electric submersible pump. The mechanical seals208-214can prevent fluid from entering the seal135around the shaft206through the guide tube204. The seal bags216-220can further isolate the electric motor and prevent ingress of wellbore fluid due to the failure of one of the mechanical seals208-214. For example, the seal bags216-220may be elastomeric and can provide a barrier to isolate the wellbore fluid from the electric motor. In this example, the three sections in the seal135and the seal bags216-220may provide redundant protection for the electric motor120. If one of the three sections fails, the electric motor can still function without contamination from wellbore fluid. The seal bags216-220in the sections may have the ability to self-heal according to some examples of the present disclosure. Each of seal bags216-220can include an inner layer and an outer layer. The outer layer may be resistant to polar fluids and hydrocarbons found in wellbore fluid. The inner layer may be material that is water-sensitive or otherwise sensitive to other polar substances and that can swell in response to contact with water or other polar substances. In an example, if one of the mechanical seals208-214fails, the seal section below the failed mechanical seal can fill with wellbore fluid. The seal bag in the failed section may develop a tear in the outer layer and the inner layer of the seal bag may be exposed to wellbore fluid. The inner layer may swell in response to the wellbore fluid to fill the tear. The inner layer can seal the tear in the outer layer preventing or limiting the ingress of wellbore fluid into the seal and can maintain isolation of the motor oil and motor from the wellbore fluid. FIG.3is a cross-sectional schematic of a seal135that includes a seal bag220that has multiple layers according to one example of the present disclosure. The seal135can have an outer housing202that can be a pipe that may be bounded at each end by a head and a base. Check valves within the head and base can allow motor oil to move within the seal135for maintaining a constant and slightly positive pressure through the seal135relative to ambient wellbore pressure at the pump intake. The seal bag220can be positioned inside the outer housing202in the seal section between mechanical seals212,214. A guide tube204can be positioned axially within the seal135and can define a cavity in which a shaft206can rotate to transfer power from the electric motor to the pump of an electric submersible pump. The seal bag220can be positioned around the guide tube204. The guide tube204can provide a path for motor oil to fill the seal bag220and can maintain adequate clearance between the shaft206and the seal bag220. Motor oil can fill both an interior area302of the seal bag220and the external area304that is inside the outer housing202and external to the seal bag220. If the mechanical seal212fails, the seal section between the mechanical seals212and214can be contaminated with wellbore fluid. In this example, the seal bag220can protect the next section of the seal135from being contaminated and can maintain the isolation of the motor oil and the electric motor from wellbore fluid. The seal bag220has multiple layers. The outer layer may be resistant to polar fluids and hydrocarbons in wellbore fluid. The inner layer may be a water-sensitive or polar-substance sensitive polymer that can swell. If the seal bag220develops a tear in the outer layer, the inner layer of the seal bag220may be exposed to wellbore fluid. The inner layer may swell in response to contact with water or other polar substances and press the outer layer against the inside surface of the outer housing202to seal the tear. The response of the inner layer can seal the tear in the outer layer to prevent or limit the ingress of wellbore fluid into the seal bag220. FIG.4is cross-sectional schematic of part of a seal that includes two layers of a seal bag220and an outer housing202according to one example of the present disclosure. The two layers include an inner layer402and an outer layer404. Both the inner layer402and the outer layer404of the seal bag220can be positioned in an inner area defined by the outer housing202for an electric submersible pump. The outer layer404can be positioned adjacent to the outer housing202and between the outer housing202and the inner layer402. In some examples, the inner layer402may be coupled to the outer layer404. For example, the inner layer402and the outer layer404can be formed together in a mold or die. In other examples, the inner layer402and outer layer404may be separate layers that are uncoupled and can be assembled, with the inner layer402inside the outer layer404, and mounted within the seal. In still other examples, the inner layer402and the outer layer404are formed by different single-layer bags with one bag being the inner layer402and the other bag being the outer layer404. The outer layer404can be made from an elastomeric material that may swell in response to wellbore fluids, gases, pressure changes, or temperature changes. The elastomeric material can be capable of swelling and deswelling multiple times while maintaining its integrity, such as by maintaining fluid isolation properties in both the swell and deswell states. Examples of the elastomeric material from which the outer layer404can be made include AFLAS®, Viton®, Highly Saturated Nitrile (HSN), styrene butadiene, acrylonitrile butadiene rubber, hydrogenated acrylonitrile butadiene rubber, carboxlyated acrylonitrile butadiene rubber, ethylene vinyl acetate, ethylene acrylate, vinyl methyl silicone, Hypalon®, ethylene copolymer, tetrafluoroethylene propylene, ethylene propylene diene monomer, and combinations of these or other suitable materials. The inner layer402can be made from a polymer that may be resistant to motor oil and that may swell in response contact with water and other polar substances. Examples of polymers from which the inner layer402may be made include a hydrophobic polymer, a polymer blend with crosslinked hydrogel such as polyacrylate, polyvinyl alcohol, polyethylene oxide, starch-acrylate copolymer, carboxymethyl cellulose, or combinations of these or other suitable material. A tear in the seal bag220, such as a tear in the outer layer404, may allow wellbore fluid to enter into an inner area defined by the inner layer402. The inner layer402can respond to contact with water or other polar substances in the wellbore fluid by swelling toward the outer layer404and the outer housing202. The swelling inner layer402may force the outer layer404against the outer housing202and seal the tear in the seal bag220by preventing wellbore fluid from entering the inner area defined by the inner layer402. The ability of the inner layer402of the seal bag to swell in response to polar substances and fill a tear in the seal bag220can provide the seal bag220the ability to self-heal a tear in the seal bag220in the downhole environment. In some examples, the outer layer404may include a surface facing the outer housing202and the surface can include a slick or anti-stick substance that can promote movement of the seal bag220along an inner surface of the outer housing202and that may prevent friction coupling. Friction coupling can include a coupling between the outer layer404and the outer housing202due to resistance between the two components. Friction coupling between the outer layer404and the outer housing202can result in the seal bag220sticking and bunching, that can lead to the seal bag220tearing. The slick or anti-slick substance, such as Teflon®, can be used to prevent or reduce friction coupling. In addition or alternatively, the outer housing202can include a substance, such as Teflon®, on an inner surface of the outer housing202to prevent or reduce friction coupling with the outer layer404. FIG.5is cross-sectional schematic of a seal that includes more than two layers of a seal bag504and an outer housing502according to one example of the present disclosure. The layers of the seal bag504can be positioned within an inner area defined by the outer housing502of the seal for an electric submersible pump. The seal bag504layers include: an outer layer506, an inner layer510, and at least one middle layer508. The outer layer506and the inner layer510may be the same or similar to the inner layer402and the outer layer404ofFIG.4. The outer layer506can be positioned adjacent to the inside surface of the outer housing502and between the outer housing502and the middle layer508. The middle layer508is positioned between the inner layer510and the outer layer506of seal bag504. The middle layer508may be made from a material that can add stiffness, other structural support, permeability resistance, or other beneficial effects to the seal bag504. An inner layer510may be made from a polymer that may be resistant to motor oil and that may respond to water and other polar substances by swelling. In one example, if the seal integrity is compromised, wellbore fluid may infiltrate seal bag504. A tear in the outer layer506and the middle layer508of the seal bag504can allow wellbore fluid to penetrate to the inner layer510that can swell in response to a polar substance, such as water, in the wellbore fluid. The inner layer510can swell into the tear in the outer layer506and the middle layer508to force the outer layer506against the inner surface of the outer housing502and seal the tear. Sealing the tear can reduce or prevent the motor oil from being contaminated and can reduce or prevent the electric motor from failing from contaminated motor oil. The middle layer508of seal bag504may be one layer or more than one layer. The middle layer508may be coupled to at least one of the inner layer510or the outer layer506. Alternatively, the middle layer508may be assembled with the inner layer510and the outer layer506as separate bags to form the seal bag504. In some examples, the middle layer508is a tape or a mesh material that can support the structure of the seal bag504during swell and deswell. An example of the tape material can be Teflon® or other suitable tape. An example of the mesh material may be a nylon mesh or other mesh material that can provide structural support. In other examples, the middle layer508can be a material that can support permeability resistance of the seal bag504. For example, the middle layer508can be a material similar to that of the outer layer506that is resistant to wellbore fluid and that provides additional protection to the inner layer510. In still other examples, the middle layer508can be a liquid contained between the inner layer510and the outer layer506that responds to water and other polar substances by swelling. The liquid that forms the middle layer508may aid the inner layer510in sealing a tear in the outer layer506. In another example, the middle layer508can be a liquid that may swell when exposed to water and other polar substances in the wellbore fluid. The inner layer510in this example may be similar to the outer layer506in material and function. If a tear forms in the outer layer506of the seal bag504, the middle layer508can swell in response to the polar substances in the wellbore fluid and fill the tear in the outer layer506. FIG.6is a flowchart of a process600for sealing a tear in an outer layer of a seal bag with an inner layer according to one example of the present disclosure. In block602, an electric submersible pump is run downhole into a wellbore. The electric submersible pump can be run downhole using a conveyance mechanism such as coiled tube or wireline. The electric submersible pump can include an electric motor and a pump coupled by a shaft that transmits power from the electric motor to the pump. The electric motor can power the pump so that the pump provides artificial lift for the wellbore. A seal can be positioned between the electric motor and the pump. The seal can include a seal bag that has an inner layer and an outer layer in an outer housing. The seal bag may contain the inner layer and the outer layer, or may include one or more layers in addition to the inner layer and the outer layer. The seal including the seal bags can isolate the electric motor from wellbore fluids. In block604, the outer layer of a seal bag swells to contact the inner surface of the outer housing of the seal. The outer layer of the seal bag may be an elastomeric material and can swell and deswell in response to pressure changes, temperature changes, or exposure to wellbore fluid or gases. During pump operation, the outer layer of the seal bag can swell to contact an inner surface of the outer housing of the seal that is a section of a pipe. The outer housing provides structural support for the bag to limit the swell of the bag. In block606, the inner layer of a seal bag swells to repair a tear in the outer layer. During operation of the electric submersible pump, the outer layer of the seal bag can experience a cycle of swell and deswell that can cause the elastomeric material of the outer layer to tear. The tear can expose the inner layer of the bag to wellbore fluid. The inner layer of the seal bag may be a material that responds to polar substances in the wellbore fluid by swelling. The inner layer of the seal bag can swell into the tear to seal the tear in the outer layer and press the outer layer against the inner surface of the outer housing of the seal. This self-heal action can prevent or restrict the contamination by wellbore fluid of the motor oil and electric motor of the electric submersible pump. In some aspects, electric submersible pumps, seals, and methods for self-healing tears in a seal bag are provided according to one or more of the following examples: Example 1 is an electric submersible pump, comprising: a pump; an electric motor that is coupled to the pump; and a seal positioned between the pump and the electric motor, the seal having an outer housing and a seal bag internal to the outer housing, the seal bag including an outer layer and an inner layer, the outer layer being made from a first material to retain a structure of the outer layer in a swellable state in a wellbore, the inner layer being made from a second material that is swellable in the wellbore in response to contact with a polar substance to seal a tear in the outer layer. Example 2 is the electric submersible pump of example 1, wherein the outer layer of the seal bag has a surface to prevent friction coupling of the outer layer in the swellable state to an inside surface of the outer housing. Example 3 is the electric submersible pump of example 1, wherein the seal bag includes a middle layer between the inner layer and the outer layer. Example 4 is the electric submersible pump of example 3, wherein the middle layer is at least one of a mesh material or a tape material. Example 5 is the electric submersible pump of example 3, wherein the middle layer is a liquid. Example 6 is the electric submersible pump of example 1, wherein the outer layer is positioned between the inner layer and the outer housing, wherein the outer layer is swellable to the swellable state to contact the outer housing, wherein the inner layer is swellable in response to contact with the polar substance to exhibit a force on the outer layer toward the outer housing to seal the tear in the outer layer to prevent fluid from the wellbore from contacting the electric motor. Example 7 is the electric submersible pump of example 6, wherein the seal bag defines a chamber in which a shaft is positioned to provide mechanical communication between the electric motor and the pump. Example 8 is the electric submersible pump of example 1, wherein the outer housing has an inside surface with a coating to prevent friction coupling between the inside surface of the outer housing and the outer layer. Example 9 is a seal comprising: an outer housing positionable between a pump and an electric motor of an electric submersible pump; and a seal bag internal to the outer housing, the seal bag including an outer layer and an inner layer, the outer layer being made from a first material to retain a structure of the outer layer in a swellable state in a wellbore, the inner layer being made from a second material that is swellable in the wellbore in response to contact with a polar substance to seal a tear in the outer layer. Example 10 is the seal of example 9, wherein the outer layer of the seal bag has a surface to prevent friction coupling of the outer layer in the swellable state to an inside surface of the outer housing of the seal. Example 11 is the seal of example 9, wherein the seal bag includes a middle layer between the inner layer and the outer layer. Example 12 is the seal of example 9, wherein the outer layer is positioned between the inner layer and the outer housing, wherein the outer layer is swellable to the swellable state to contact the outer housing, wherein the inner layer is swellable in response to contact with the polar substance to exhibit a force on the outer layer toward the outer housing to seal the tear in the outer layer to prevent fluid from the wellbore from contacting the electric motor. Example 13 is the seal of example 9, wherein the outer layer is made from an elastomeric, wherein the inner layer is made from a polymer that includes at least one of a hydrophobic polymer or a polymer blend with crosslinked hydrogel. Example 14 is the seal of example 9, wherein the seal bag defines a chamber within the seal through which a shaft is positionable to provide mechanical communication between an electric motor and a pump. Example 15 is a method comprising: running an electric submersible pump into a wellbore, the electric submersible pump including a pump, an electric motor coupled to the pump, and a seal, the seal including an outer housing and a seal bag internal to the outer housing, the seal bag including an outer layer and an inner layer; swelling, by the outer layer while retaining a structure of the outer layer, to contact the outer housing; and swelling, by the inner layer, to seal a tear in the outer layer in response to the inner layer contacting a polar substance. Example 16 is the method of example 15, wherein swelling, by the outer layer while retaining the structure of the outer layer, to contact the outer housing comprises: preventing friction coupling between the outer layer and an inside surface of the outer housing by a surface of the outer layer. Example 17 is the method of example 15, wherein the seal bag further includes a middle layer between the inner layer and the outer layer. Example 18 is the method of example 15, wherein the outer layer is positioned between the inner layer and the outer housing, wherein swelling, by the inner layer, to seal the tear in the outer layer in response to the inner layer contacting the polar substance comprises the inner layer exhibiting a force on the outer layer toward the outer housing to seal the tear in the outer layer to prevent fluid from the wellbore from contacting the electric motor. Example 19 is the method of example 15, further comprising: preventing, by a coating on an inside surface of the outer housing, the inside surface of the outer housing from forming a friction coupling with the outer layer. Example 20 is the method claim15, further comprising: mechanically coupling, by a shaft within a chamber defined by the seal bag, the electric motor to the pump. The foregoing description of certain examples, including illustrated examples, has been presented only for the purpose of illustration and description and is not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Numerous modifications, adaptations, and uses thereof will be apparent to those skilled in the art without departing from the scope of the disclosure. | 29,289 |
11859476 | DETAILED DESCRIPTION In the following detailed description of embodiments of the disclosure, numerous specific details are set forth in order to provide a more thorough understanding of the disclosure. However, it will be apparent to one of ordinary skill in the art that the disclosure may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description. Throughout the application, ordinal numbers (e.g., first, second, third, etc.) may be used as an adjective for an element (i.e., any noun in the application). The use of ordinal numbers is not to imply or create any particular ordering of the elements nor to limit any element to being only a single element unless expressly disclosed, such as using the terms “before”, “after”, “single”, and other such terminology. Rather, the use of ordinal numbers is to distinguish between the elements. By way of an example, a first element is distinct from a second element, and the first element may encompass more than one element and succeed (or precede) the second element in an ordering of elements. FIG.1shows an exemplary ESP system (100) in accordance with one or more embodiments. The ESP system (100) is used to help produce produced fluids (102) from a formation (104). Perforations (106) in the well's (116) casing (108) provide a conduit for the produced fluids (102) to enter the well (116) from the formation (104). The ESP system (100) includes a surface portion having surface equipment (110) and a downhole portion having an ESP string (112). The ESP string (112) is deployed in a well (116) on production tubing (117) and the surface equipment (110) is located on a surface location (114). The surface location (114) is any location outside of the well (116), such as the Earth's surface. The production tubing (117) extends to the surface location (114) and is made of a plurality of tubulars connected together to provide a conduit for produced fluids (102) to migrate to the surface location (114). The ESP string (112) may include a motor (118), motor protectors (120), a gas separator (122), a multi-stage centrifugal pump (124) (herein called a “pump” (124)), and a power cable (126). The ESP string (112) may also include various pipe segments of different lengths to connect the components of the ESP string (112). The motor (118) is a downhole submersible motor (118) that provides power to the pump (124). The motor (118) may be a two-pole, three-phase, squirrel-cage induction electric motor (118). The motor's (118) operating voltages, currents, and horsepower ratings may change depending on the requirements of the operation. The size of the motor (118) is dictated by the amount of power that the pump (124) requires to lift an estimated volume of produced fluids (102) from the bottom of the well (116) to the surface location (114). The motor (118) is cooled by the produced fluids (102) passing over the motor (118) housing. The motor (118) is powered by the power cable (126). The power cable (126) is an electrically conductive cable that is capable of transferring information. The power cable (126) transfers energy from the surface equipment (110) to the motor (118). The power cable (126) may be a three-phase electric cable that is specially designed for downhole environments. The power cable (126) may be clamped to the ESP string (112) in order to limit power cable (126) movement in the well (116). Motor protectors (120) are located above (i.e., closer to the surface location (114)) the motor (118) in the ESP string (112). The motor protectors (120) are a seal section that houses a thrust bearing. The thrust bearing accommodates axial thrust from the pump (124) such that the motor (118) is protected from axial thrust. The seals isolate the motor (118) from produced fluids (102). The seals further equalize the pressure in the annulus (128) with the pressure in the motor (118). The annulus (128) is the space in the well (116) between the casing (108) and the ESP string (112). The pump intake (130) is the section of the ESP string (112) where the produced fluids (102) enter the ESP string (112) from the annulus (128). The pump intake (130) is located above the motor protectors (120) and below the pump (124). The depth of the pump intake (130) is designed based off of the formation (104) pressure, estimated height of produced fluids (102) in the annulus (128), and optimization of pump (124) performance. If the produced fluids (102) have associated gas, then a gas separator (122) may be installed in the ESP string (112) above the pump intake (130) but below the pump (124). The gas separator (122) removes the gas from the produced fluids (102) and injects the gas (depicted as separated gas (132) inFIG.1) into the annulus (128). If the volume of gas exceeds a designated limit, a gas handling device may be installed below the gas separator (122) and above the pump intake (130). The pump (124) is located above the gas separator (122) and lifts the produced fluids (102) to the surface location (114). The pump (124) has a plurality of stages that are stacked upon one another. Each stage contains a rotating impeller and stationary diffuser. As the produced fluids (102) enter each stage, the produced fluids (102) pass through the rotating impeller to be centrifuged radially outward gaining energy in the form of velocity. The produced fluids (102) enter the diffuser, and the velocity is converted into pressure. As the produced fluids (102) pass through each stage, the pressure continually increases until the produced fluids (102) obtain the designated discharge pressure and has sufficient energy to flow to the surface location (114). A packer (142) is disposed around the ESP string (112). Specifically, the packer (142) is located above (i.e., closer to the surface location (114)) the multi-stage centrifugal pump (124). The packer (142) may be any packer (142) known in the art such as a mechanical packer (142). The packer (142) seals the annulus (128) space located between the ESP string (112) and the casing (108). This prevents the produced fluids (102) from migrating past the packer (142) in the annulus (128). In other embodiments, sensors may be installed in various locations along the ESP string (112) to gather downhole data such as pump intake volumes, discharge pressures, and temperatures. The number of stages is determined prior to installation based of the estimated required discharge pressure. Over time, the formation (104) pressure may decrease and the height of the produced fluids (102) in the annulus (128) may decrease. In these cases, the ESP string (112) may be removed and resized. Once the produced fluids (102) reach the surface location (114), the produced fluids (102) flow through the wellhead (134) into production equipment (136). The production equipment (136) may be any equipment that can gather or transport the produced fluids (102) such as a pipeline or a tank. The remainder of the ESP system (100) includes various surface equipment (110) such as electric drives (137) and pump control equipment (138) as well as an electric power supply (140). The electric power supply (140) provides energy to the motor (118) through the power cable (126). The electric power supply (140) may be a commercial power distribution system or a portable power source such as a generator. The pump control equipment (138) is made up of an assortment of intelligent unit-programmable controllers and drives which maintain the proper flow of electricity to the motor (118) such as fixed-frequency switchboards, soft-start controllers, and variable speed controllers. The electric drives (137) may be variable speed drives which read the downhole data, recorded by the sensors, and may scale back or ramp up the motor (118) speed to optimize the pump (124) efficiency and production rate. The electric drives (137) allow the pump (124) to operate continuously and intermittently or be shut-off in the event of an operational problem. For many ESP completion systems, such as the ESP system (100) depicted inFIG.1, there is no way to access the portion of the well (116) located beneath (i.e., further away from the surface location (114)) the ESP string (112) without completely removing the ESP string (112). Therefore, systems that allow through-tubing access to the portion of the well (116) located beneath the ESP string (112) are beneficial. As such, embodiments presented herein disclose a Y-tool that may be used to employ a bypass tubing that provides a conduit for a through-tubing tool to by-pass the ESP string (112) and access deeper portions of the well (116). FIG.2shows a Y-tool (200) in accordance with one or more embodiments. The Y-tool (200) includes a crossover (202), a telescoping joint (204), and a pump sub (206). The crossover (202) of the Y-tool is a tubular that is hydraulically connected to production tubing (117). The production tubing (117) extends to the surface location (114). The production tubing (117) provides a hydraulic connection from the surface location (114) to a depth in the well (116). The crossover (202) is physically connected to the production tubing (117) by any means in the art such as by a threaded connection. The crossover (202) provides the hydraulic connection from the production tubing (117) to the telescoping joint (204) and the pump sub (206). The telescoping joint (204) and the pump sub (206) may be hydraulically and physically connected to the crossover (202) but not to one another. The telescoping joint (204) and the pump sub (206) may be parallel to one another once each are connected to the crossover (202). The telescoping joint (204) and the pump sub (206) are physically connected to the crossover (202) by any means known in the art such as by a threaded connection. The pump sub (206) is a tubular that may be similar to the tubulars that make up the production tubing (117). The pump sub (206) may be connected to the crossover (202) and an ESP string (112), such as the ESP string (112) depicted inFIG.1. The crossover (202) and the ESP string (112) may be connected on opposite ends of the pump sub (206) from one another. The telescoping joint (204) includes a housing (208) and a by-pass hanger (210). The housing (208) is a tubular connected to the crossover (202) on one end and having an opening (212) on the opposite end. The by-pass hanger (210) is also a tubular having a head (214) and a body (216). In one or more embodiments, the by-pass hanger (210) may have an outer diameter of 3.5 inches and an inner diameter of 2.992 inches. The by-pass hanger (210) may be made of steel having a grade of T95. The housing (208) is hydraulically connected to the crossover (202) and the by-pass hanger (210) is hydraulically connected to the housing (208). The opening (212) of the housing (208) is larger than the body (216) of the by-pass hanger (210) yet smaller than the head (214) of the by-pass hanger (210). The head (214) of the by-pass hanger (210) is moveably located within the inside of the housing (208). The head (214) is moveable within the housing (208) such that the head (214), along with the body (216) of the by-pass hanger (210), may move up and down within the housing (208) (up referring to the direction towards the crossover (202) and down referring to the direction away from the crossover (202)). Because the head (214) is larger than the opening (212) of the housing (208), the head (214) may not exit the housing (208) thus the by-pass hanger (210) is moveably connected to the housing (208). A lock ring (218) may be disposed around an external circumferential surface of the body (216) of the by-pass hanger (210). The lock ring (218) may be directly beneath the opening (212) when the by-pass hanger (210) is fully extended (fully extended meaning that the head (214) of the by-pass hanger (210) is resting on the opening (212) of the housing (208)). The lock ring (218) absorbs a compressive force and prevents the by-pass hanger (210) from moving in an upwards direction (i.e., in a direction towards the crossover (202)). FIG.3shows a system incorporating the Y-tool (200) in accordance with one or more embodiments. Specifically,FIG.3shows a dual bore well (300) using the Y-tool (200), as depicted inFIG.2, to bypass the ESP string (112), as depicted inFIG.1. Components shown inFIG.3that are the same as or similar to components shown inFIGS.1and2have not been re-described for purposes of readability and have the same purposes as described above. The dual bore well (300) has a main bore (302) and a lateral bore (304). The dual bore well (300) has casing (108) that extends from the surface location (114) to a depth downhole. The main bore (302) is a hole drilled into the surface of the Earth. The main bore (302) may be partially covered and supported by the casing (108). The main bore (302) may be a vertically drilled hole. In other embodiments, the main bore (302) is a directional hole drilled at an angle less than 80 degrees from vertical. The lateral bore (304) is a hole drilled at an angle greater than 80 degrees from vertical. The lateral bore (304) is located above (i.e., closer to the surface location (114)) the main bore (302). In further embodiments, the lateral bore (304) is a horizontal extension of the main bore (302). The casing (108) may end before the beginning of the lateral bore (304). In other embodiments, the lateral bore (304) was sidetracked through the surface of the casing (108) such that the casing (108) extends beneath the beginning of the lateral bore (304) as shown inFIG.3. FIG.3also shows production tubing (117) located within the casing (108) and extending to the surface location (114). The deepest point of the production tubing (117) (i.e., the end of the production tubing (117) located furthest away from the surface location (114)) is connected to the crossover (202) of the Y-tool (200). The crossover (202) is connected to the telescoping joint (204) and the pump sub (206). The pump sub (206) is connected to the ESP string (112). The by-pass hanger (210) of the telescoping joint (204) is hydraulically and physically connected to by-pass tubing (308). The ESP string (112) may need to be designed with a multi-stage centrifugal pump (124) having a smaller outer diameter than normal in order to fit the telescoping joint (204) and by-pass tubing (308) next to the ESP string (112). The by-pass tubing (308) is a tubular similar to the tubular of the by-pass hanger (210). The connection between the by-pass tubing (308) and the by-pass hanger (210) is a flush joint connection and may be a threaded connection. The connection between the ESP string (112) and the pump sub (206) may by any connection known in the art such as a threaded connection. The by-pass tubing (308) may be hydraulically and physically connected to a stinger (310). A power cable (126) may extend from the surface location (114), along the production tubing (117) to the stinger (310). The stinger (310) is inserted into a hydraulic-line wet-mate connector (HLWM) (312). The stinger (310) may provide the hydraulic connection between the surface location (114), the main bore (302) and the lateral bore (304). The stinger (310) may have a plurality of seals disposed around the outside of the stinger (310) such that the stinger (310) may create a fluid-tight seal while inserted into the HLWM (312). The HLWM (312) is connected to a pipe (314). The pipe (314) may be part of a pipe (314) assembly having the HLWM (312), a first packer (316), a second packer (318), a first inflow control valve (ICV) (320), a second ICV (322), and a selective lateral intervention completion (SLIC) (324) system. The pipe (314) may be made out of the same tubular as the production tubing (117). The pipe (314) is hydraulically connected to the main bore (302) and the lateral bore (304). The first packer (316) and the second packer (318) are disposed circumferentially around the pipe (314) and create a seal within the annulus (128) located between the pipe (314) and the casing (108). The first packer (316) and the second packer (318) may be any packer (142) known in the art, such as the packer (142) described inFIG.1. The HLWM (312) provides a mechanical, electrical, and hydraulic connection between the stinger (310)/power cable (126) and the pipe (314). The HLWM (312) allows the completion of the dual bore well (300) to be executed in multiple stages. For example, the pipe (314) assembly may be run into the casing (108) prior to the production tubing (117)/ESP string (112) assembly being run into the casing (108). In one or more embodiments, the pipe (314) assembly may be run in the casing (108) on a wireline (326). The first packer (316) and the second packer (318) may be set against the casing (108) allowing the pipe (314) assembly to be held up in the casing (108). The wireline (326) may detach from the pipe (314) assembly leaving the pipe (314) assembly behind. The production tubing (117) may run the ESP string (112)/Y-tool (200) assembly into the casing (108). The stinger (310) may enter or “sting into” the HLWM (312) to connect the pipe (314) assembly hydraulically, mechanically, and electrically to the production tubing (117)/ESP string (112) assembly. The HLWM (312) is located above (above meaning closer to the surface location (114)) the first packer (316), the first packer (316) is located above the first ICV (320), the first ICV (320) is located above the second ICV (322), the second ICV (322) is located above the SLIC (324) system, and the SLIC (324) system is located above the second packer (318). The first packer (316) is located above the lateral bore (304) yet below the by-pass hanger (210). The second packer (318) is located above the main bore (302) yet beneath the lateral bore (304). The pipe (314) may extend past the second packer (318) and into the main bore (302) such that produced fluids (102) may flow from the main bore (302) into the pipe (314). The first packer (316) prevents produced fluids (102) from migrating up the annulus (128) towards the ESP string (112). The second packer (318) prevents produced fluids (102) from migrating from the main bore (302) to the lateral bore (304). The first ICV (320) and the second ICV (322) are active components that partially or completely choke flow into the pipe (314) from the main bore (302) and the lateral bore (304). The first ICV (320) and the second ICV (322) may be controlled from the surface location (114) to maintain flow conformance and, as the formation(s) deplete, to stop unwanted produced fluids (102) from entering the pipe (314). A power cable (126) provides electric and hydraulic conduits to relay commands from the surface location (114) to the first ICV (320) and the second ICV (322). Specifically, the first ICV (320) controls a flow of produced fluids (102) from both the lateral bore (304) and the main bore (302). The second ICV (322) controls a flow of produced fluids (102) from the main bore (302). The SLIC (324) system enables through-tubing intervention in multilateral wells such as the dual bore well (300). The SLIC (324) system may be used to access the lateral bore (304) or to hydraulically isolate the lateral bore (304) from the main bore (302). Multiple SLIC (324) systems can be installed for selective intervention access when a well has multiple lateral bores (304). In one or more embodiments the SLIC (324) system may allow selective through-tubing access to either the lateral bore (304) or the main bore (302).FIG.3shows a through-tubing tool (328) run in the dual bore well (300) on the wireline (326). The through-tubing tool (328) may be any type of downhole tool that may be used to perform a workover operation on the main bore (302) or on the lateral bore (304). Because of the Y-tool (200) and the completion design, as outlined inFIG.3, the through-tubing tool (328) is able to enter the production tubing (117) at the surface location (114), by-pass the ESP string (112), and enter either the main bore (302) or the lateral bore (304) using the SLIC (324) system. Further, the Y-tool (200), as designed inFIG.2, is able to both space out the by-pass tubing (308) from the ESP string (112) as they are being run in the casing (108) and absorb the compression force when the stinger (310) is landed out into the HLWM (312). WhileFIG.3shows the Y-tool (200) being used to by-pass the ESP string (112) in a dual bore well (300) any well such as a well having more than two bores or a well having a singular bore, such as the well (116) depicted inFIG.1, may be used. Further, the completion scheme of the well may be any completion scheme that includes the Y-tool (200), as described inFIG.2, to by-pass an ESP string (112) without departing from the scope of this disclosure herein. FIG.4shows a flowchart in accordance with one or more embodiments. Specifically, the flowchart illustrates a method for by-passing an ESP string (112) in a dual bore well (300) to access a main bore (302) and a lateral bore (304). Further, one or more blocks inFIG.4may be performed by one or more components as described inFIGS.1-3. While the various blocks inFIG.4are presented and described sequentially, one of ordinary skill in the art will appreciate that some or all of the blocks may be executed in different orders, may be combined or omitted, and some or all of the blocks may be executed in parallel. Furthermore, the blocks may be performed actively or passively. Initially, an ESP string (112) is installed on production tubing (117) within a well (S400). The ESP string (112) may be the ESP string (112) as depicted inFIG.1. The well may be a dual bore well (300) having a main bore (302) and a lateral bore (304) as depicted inFIG.3. The production tubing (117) extends from a surface location (114) to a depth within the dual bore well (300). The ESP string (112) may be installed to a pump sub (206) of a Y-tool (200), such as the Y-tool depicted inFIG.2. The Y-tool (200) may be connected to the production tubing (117) through the Y-tool's (200) crossover (202). By-pass tubing (308) may be installed on the telescoping joint (204) of the Y-tool (200). Installing the ESP string (112) in the dual bore well (300) may include running a pipe (314) assembly, as depicted inFIG.3, into the dual bore well (300) on wireline (326). The pipe (314) assembly may have a HLWM (312), a first packer (316), a second packer (318), a first ICV (320), a second ICV (322), and a SLIC (324) system (all installed onto the pipe (314)). The pipe (314) assembly may be hydraulically connected to the main bore (302) and the lateral bore (304). The HLWM (312) may be hydraulically connected to the pipe (314). The second packer (318) may be set within the casing (108) above the main bore (302) and below the lateral bore (304). The first packer (316) may be set above the lateral bore (304). After the first packer (316) and the second packer (318) are set, the ESP string (112) may be run in the dual bore well (300) on the production tubing (117). The telescoping joint (204) allows the by-pass tubing (308) to be spaced out from the ESP string (112) as they are being run into the dual bore well (300). A stinger (310), connected to the by-pass tubing (308), may be inserted into the HLWM (312) to create a hydraulic connection between the lateral bore (304), the main bore (302), and the surface location (114). The insertion of the stinger (310) into the HLWM (312) also creates a mechanical and electrical connection between the surface location (114) and the pipe (314) assembly. As the stinger (310) is inserted into the HLWM (312), a compressive force is transferred to the stinger (310), to the by-pass tubing (308), and to the by-pass hanger (210). The compressive force is absorbed by the lock ring (218), thus preventing the compressive force from being transferred to the ESP string (112). If the compressive force were to be transferred to the ESP string (112), the motor (118) and the multi-stage centrifugal pump (124) of the ESP string (112) may fail. Upon insertion of the stinger (310) into the HLWM (312), the dual bore well may be placed on production. Over the life of the dual bore well (300), a workover operation may need to be performed. During the workover operation, a through-tubing tool (328) is run through the production tubing (117) (S402). The through-tubing tool (328) is able to by-pass the ESP string (112) using the Y-tool (200) to access a section of the well located below the ESP string (112) (S404). Specifically, the through-tubing tool (328) may enter the production tubing (117) at the surface location (114). The through-tubing tool (328) may be run on wireline (326). The through-tubing tool (328) may be run through the crossover, the by-pass hanger, and the by-pass tubing (308) to by-pass the ESP string (112). The through-tubing tool (328) may enter either the lateral bore (304) or the main bore (302) using the SLIC (324) system. Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. § 112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function. | 26,279 |
11859477 | DETAILED DESCRIPTION The invention will now be described in more detail without limitation in the following description. The invention may relate to a method for extracting hydrocarbons from a subterranean formation, comprising:injecting a fluid into the subterranean formation during a first period of time,not injecting said fluid during a second period of time, andcollecting hydrocarbons displaced by the injected fluid, wherein:the fluid injection during the first period of time is at least partly carried out using solar energy and/orthe method further comprises a step of producing a carbon dioxide stream using solar energy. Advantageously, the carbon dioxide stream is injected as a fluid into the subterranean formation. More preferably, it is injected as a fluid into the subterranean formation during the first period of time. Thus, at least part of the fluid injected into the subterranean formation to displace hydrocarbons may be produced using solar energy, making it possible to reduce fuel energy consumption. The step of producing a carbon dioxide stream is one embodiment of the fluid provision step of the method of the invention. By “fluid” is meant any gas, liquid or supercritical fluid, or any mixture thereof. In some embodiments, the first period of time is at least part of daytime and the second period of time is at least part of nighttime. In particular embodiments, the first period of time is substantially the whole daytime and/or the second period of time is substantially the whole nighttime. By “daytime” is preferably meant the period in which there is solar availability, that is to say in which sunlight is available, including when the sky is cloudy. Preferably, “daytime” means the period from sunrise to sunset and more preferably the period in which illuminance in the environment is higher than 10 Lux. Most preferably, illuminance in the environment is higher than 100 Lux during daytime. By “nighttime” is preferably meant the period in which there is no solar availability. Preferably, it is meant the period from sunset to sunrise and more preferably the period in which illuminance in the environment is lower than 1 Lux. Most preferably, illuminance in the environment is lower than 0.5 Lux during nighttime. The duration of daytime and nighttime varies depending on the time of the year and is therefore defined by taking into account the seasonal cycle. In addition, it also depends on the geographic position. Thus, for example beyond the Arctic Circle, daytime may last for several calendar days, or several weeks or several months, for example from 3 to 6 months. Similarly, nighttime may last for several calendar days, or several weeks or several months, for example from 3 to 6 months. In some embodiments, the first period of time is a period including the summer solstice and the second period of time is a period including the winter solstice. For example, the first period of time includes the summer and the second period of time includes the winter. Preferably, the first period of time is a period of three to nine months including, preferably centered on, the summer solstice and the second period of time is a period of three to nine months including, preferably centered on, the winter solstice. The first period of time may be a period of four to eight months, such as six months, including, preferably centered on, the summer solstice and the second period of time may be a period of four to eight months, such as six months, including, preferably centered on, the winter solstice. By “summer solstice” and “winter solstice” is meant the summer solstice and winter solstice respectively as defined at the location where the fluid is injected into the subterranean formation. In periods of time surrounding the summer solstice, the daytime periods are longer than in periods surrounding the winter solstice. Therefore, more solar energy is available in periods of time surrounding the summer solstice than in periods surrounding the winter solstice, and solar energy may be more efficiently used to produce electricity or heat. According to the invention, hydrocarbons in gaseous and/or liquid phase are recovered from a subterranean formation. Preferably, hydrocarbon recovery includes oil recovery and/or natural gas recovery. The temperature within the subterranean formation may range from 25 to 140° C., preferably from 80 to 140° C. and more preferably from 100 to 120° C. The permeability of at least a portion of the subterranean formation may range from 1×10−9to 1×105md, preferably from 1 to 100 md, as estimated by well log. Hydrocarbon Recovery—First Period of Time The invention comprises injecting a fluid into the subterranean formation during a first period of time. Preferably, said injection is performed via one or several injecting wells, while hydrocarbon collection is performed via one or more production wells. In some embodiments, the injected fluid comprises or consists of one or more gas. Preferably, the injected fluid comprises, or is, carbon dioxide and/or natural gas and/or nitrogen and/or hydrogen sulfide. More preferably, the injected fluid is carbon dioxide. Carbon dioxide may be in the form of gas or supercritical fluid. In some embodiments, the injected fluid comprises both gas and an aqueous solution. The gas may be injected simultaneously with an aqueous solution. The aqueous solution is preferably water or brine, optionally containing various additives, such as surfactants, salts, sacrificial agents, mobility control polymers, pH adjustment agents, solvents, marking agents, etc. The aqueous solution and the gas may be injected via different injection wells or via the same injection well(s), for example they can be injected via distinct inlets within a same injection well. Alternatively, the aqueous solution and the gas can be premixed and injected as one composition via the same inlet(s), although this is generally not preferred due to the high pressure drop generated by the gas/water emulsion in the well(s). Gas/water emulsions which are either generated in situ or premade are preferably characterized by a gas/water volume fraction ratio of more than 1. In some embodiments, the injected fluid comprises or is an aqueous solution, which may be as described above. In other embodiments, only gas is injected into the subterranean formation. In some embodiments, the first period of time is at least part of daytime. In advantageous embodiments, the fluid is injected into the subterranean formation during substantially the whole daytime, for example only gas, or only an aqueous solution, is injected into the subterranean formation during substantially the whole daytime. In some embodiments, only an aqueous solution is injected into the subterranean formation during a part of daytime, gas being injected into the subterranean formation another part of daytime. In some embodiments, the first period of time is a period including the summer solstice. According to the invention, the step of injecting the fluid into the subterranean formation during the first period of time may be at least partly carried out using solar energy. Advantageously, the step of injecting the fluid into the subterranean formation is carried out using solar energy during at least part of daytime. Thus, when the first period of time is, for example, at least a part of daytime, the step of injecting the fluid into the subterranean formation may be entirely carried out using solar energy. When the first period of time is, for example, a period including the summer solstice, such as a period of three to nine months including the summer solstice, solar energy may be used at least part of daytime, preferably substantially the whole daytime, to carry out the injecting step, whereas the injecting step is carried out using another type of energy, such as fossil fuel energy, during at least part of nighttime, preferably the whole nighttime. In particular, solar photovoltaic energy may be used to at least partly power one or more electrical compressors used to inject the fluid (be it a gas, or an aqueous solution, or any other fluid) into the subterranean formation. Photovoltaic energy may be produced using one or more photovoltaic panels. Preferably, the photovoltaic panels are located close to the compressors. At typical low latitudes, daytime may last from 6 to 18 hours per day, preferably from 8 to 16 hours per day, more preferably from 10 to 14 hours per day. The daytime steps (i.e. the above steps performed during the first period of time when the first period of time is at least part of daytime, preferably substantially the whole daytime) may last from 6 to 18 hours per day, preferably from 8 to 16 hours per day, more preferably from 10 to 14 hours per day. As the amount of solar energy available may be low during part of daytime, the above daytime steps may typically be performed during 8 to 10 hours per day or, typically, during 6 to 10 hours per day. At extreme latitudes where sun availability is dominated by seasonal rather than diurnal cycles, the daytime steps may be performed for longer times, for example in places where daytime lasts more than one calendar day. Thus, they may be performed for example for several calendar days, or several weeks, or several months each year. In some embodiments, the amount of solar energy generated in the early morning may be relatively low, so that the above daytime steps may be performed from a starting time which may be between 0.5 hour to 2 hours after sunrise, In some embodiments, solar energy may be somewhat accumulated and thus remain available until sunset or even for a certain period of time thereafter. Therefore, the daytime steps may be performed until an ending time which may be between 1 hour before sunset and 2 hours after sunset, preferably between 0.5 hour before sunset and 1 hour after sunset. Hydrocarbon Recovery—Second Period of Time According to the method of the invention, the fluid injected during the first period of time is not injected during the second period of time. The invention also includes embodiments in which a fluid is injected into the subterranean formation during the second period of time (for example during part of nighttime), provided that the nature or composition of the fluid is different from the fluid injected during the first period of time (for example during at least part of daytime). Preferably, the method of the invention comprises injecting an aqueous solution into the subterranean formation during at least part of the second period of time, preferably during the second period of time (for example during at least part of nighttime, or during substantially the whole nighttime). The hydrocarbons displaced by the injected aqueous solution are then collected. These embodiments are particularly advantageous when the fluid injected during the first period of time (for example during at least part of daytime) comprises or is gas. More preferably, the aqueous solution is injected into the subterranean formation when no injection of gas is performed. In certain embodiments, aqueous solution injection may be carried as soon as gas injection is stopped. The aqueous solution may be as described above. In particular, it may be water or brine, and it may comprise the abovementioned additives. The aqueous solution may be injected simultaneously with gas, provided that the fluid injected during the first period of time (for example during at least part of daytime) is not injected during the second period of time (for example during a part of nighttime). In some embodiments, no injection into the subterranean formation is carried out during at least part of the second period of time, preferably during the second period of time (for example during at least part of nighttime, or during substantially the whole nighttime), that is to say neither gas nor aqueous solution is injected. In such embodiments, fluid injection, in particular during the first period of time (for example during daytime), is adjusted, so that the pressure within the subterranean formation is maintained at a substantially constant level over time, despite a continuous extraction of hydrocarbons and a discontinuous fluid injection. In preferred embodiments, when the fluid injected during the first period of time (for example during at least part of daytime) is an aqueous solution, no injection into the subterranean formation is carried out during the second period of time (for example during at least part of nighttime, or during substantially the whole nighttime). The invention also includes embodiments wherein a certain gas (or a gas with a certain composition, for example a gas comprising mainly carbon dioxide) is injected into the subterranean formation during the first period of time and a different gas (or a gas with a different composition, for example a gas with a lower carbon dioxide proportion) is injected during the second period of time. In particular, a certain gas (or a gas with a certain composition, for example a gas comprising mainly carbon dioxide) may be injected into the subterranean formation during at least part of daytime, such as during substantially the whole daytime while a different gas (or a gas with a different composition, for example a gas with a lower carbon dioxide proportion) is injected during at least part of nighttime, such as during substantially the whole nighttime. The gas comprising mainly carbon dioxide that can be injected during the first period of time (for example during at least part of daytime, or during substantially the whole daytime) may be a carbon dioxide stream produced as described below. For example, a gas comprising from 2 to 25% by weight of carbon dioxide and from 75 to 98% by weight of methane may be injected during the second period of time (for example during at least part of nighttime, or during substantially the whole nighttime) while a different gas comprising from 70 to 99.9% of carbon dioxide and from 0.1 to 30% by weight of methane is injected during the first period of time (for example during at least part of daytime, or during substantially the whole daytime). Thus, the gas injected into the subterranean formation during the second period of time (for example during at least part of nighttime, or during substantially the whole nighttime) may be natural gas (comprising mainly methane and a lower proportion of carbon dioxide) while the gas injected into the subterranean formation during the first period of time (for example during at least part of daytime, or during substantially the whole daytime) is a carbon dioxide stream (comprising mainly carbon dioxide) obtained through a CO2capture process, preferably obtained at least partly, and more preferably completely, through production of a carbon dioxide stream using solar energy as described below, for example performed on a gas stream that is the same natural gas that is injected during the second period of time (for example during at least part of nighttime). In other examples, a gas comprising from 2 to 30% by weight of carbon dioxide and from 70 to 98% by weight of nitrogen may be injected during the second period of time (for example during at least part of nighttime or during substantially the whole nighttime) while a different gas comprising from 70 to 99.9% of carbon dioxide and from 0.1 to 30% by weight of nitrogen is injected during the first period of time (for example during at least part of daytime or during substantially the whole daytime). Thus, the gas injected into the subterranean formation during the second period of time (for example during at least part of nighttime or during substantially the whole nighttime) may be a flue gas stream (comprising mainly nitrogen and a lower proportion of carbon dioxide) while the gas injected into the subterranean formation during the first period of time (for example during at least part of daytime, or during substantially the whole daytime) is a carbon dioxide stream (comprising mainly carbon dioxide) obtained through a CO2capture process, preferably obtained at least partly, and more preferably completely, through production of a carbon dioxide stream using solar energy as described below, for example performed on a gas stream that is the same flue gas stream that is injected during the second period of time (for example during at least part of nighttime). In some embodiments, the first period of time is at least part of daytime and the second period of time is at least part of nighttime. In advantageous embodiments, the second period of time is substantially the whole nighttime. The above nighttime steps (i.e. the above steps performed during the second period of time when the second period of time is at least part of nighttime, preferably substantially the whole nighttime) may be performed for example for 6 to 18 hours per day, preferably from 8 to 16 hours per day, more preferably from 10 to 14 hours per day. As the amount of solar energy available may be low during part of daytime, the above nighttime steps may typically be performed during 14 to 16 hours per day. They may also be performed for longer times, for example in places where nighttime lasts more than one calendar day. Thus, they may be performed for example for several calendar days, or several weeks, or several months per year. In certain embodiments, the fluid injected during at least part of daytime may be water, and power for said water injection may be derived from solar energy. In this embodiment, water injection may occur for at least part of daytime, or during substantially the whole daytime, whereas no injection may occur during at least part of nighttime, or substantially during the whole nighttime. In high latitudes, this injection may last for several weeks or months. In some embodiments, the first period of time is a period including the summer solstice and the second period of time is a period including the winter solstice. In certain embodiments, the fluid injected during a period including the summer solstice, for example during a period of three to nine months centered on the summer solstice, may be a gas, while no injection, or injection of an aqueous solution, or injection of a gas with a different composition, such as described above, may be carried during a period including the winter solstice, for example during a period of three to nine months centered on the winter solstice. For example, a gas comprising mainly carbon dioxide, preferably obtained at least partly through production of a carbon dioxide stream using solar energy as described below, may be injected during a period including the summer solstice, for example during a period of three to nine months centered on the summer solstice, while a gas with a lower carbon dioxide proportion, preferably natural gas or a flue gas stream, may be injected during a period including the winter solstice, for example during a period of three to nine months centered on the winter solstice. Preferably, a gas is injected during a period including the summer solstice, for example during a period of three to nine months centered on the summer solstice, while no injection is carried during a period including the winter solstice, for example during a period of three to nine months centered on the winter solstice. Cyclic Extraction Preferably, the above described steps are implemented on a cyclic basis, that is to say, they are repeated, for example every 24 hours (in particular when the first and second periods of time are respectively at least part of daytime and nighttime) or at a lower frequency (in particular, when the first and second periods of time are respectively at least part of daytime or nighttime, if daytime and/or nighttime last longer than 24 hours, or when the first and second periods of time are respectively a period of time including the summer and winter solstices), such as every year. Thus, advantageously, the method comprises a step of injecting a fluid into the subterranean formation during the first period of time (for example during at least part of daytime, such as substantially the whole daytime), every first period of time (for example every daytime period) and a step of not injecting said fluid during the second period of time (for example during at least part of nighttime)—and optionally a step of injecting an aqueous solution during at the second period of time (for example during at least a part of nighttime, such as substantially the whole nighttime)—every second period of time (for example nighttime period), for a certain period of time. This period of time may be of at least 1 calendar day, or at least 1 week, or at least 1 month, or at least 2 months, or at least 3 months, or at least 4 months, or at least 6 months, or at least 1 year, or at least 5 years, or at least 10 years. Carbon Dioxide Production The method of the invention may comprise a step of producing a carbon dioxide stream using solar energy. Preferably, this step is carried out during at least part of daytime. More preferably, this step is carried out during substantially the whole daytime. Advantageously, the step of producing a carbon dioxide stream using solar energy is carried out during at least part of daytime, simultaneously with the step of injecting the fluid into the subterranean formation. In preferred embodiments, the carbon dioxide stream produced during at least part of daytime is injected into the subterranean formation as a fluid. The carbon dioxide stream may be injected into the subterranean formation in the form of a gas or a supercritical fluid. The carbon dioxide stream produced using solar energy may be directly used, preferably by being injected into the subterranean formation. These embodiments have the advantage that no gas storage is needed. Alternatively, or in addition, the carbon dioxide stream produced using solar energy may be stored, for example for a period of time of 1 minute to 6 months, or for a period of time of 1 minute to 12 hours. The stored carbon dioxide stream may be used later, in particular carbon dioxide may be injected into the subterranean formation during part of nighttime. Carbon dioxide may be stored in tanks. Alternatively, or in addition, it may be stored in pipelines, for example by increasing the pressure in the pipelines, and then released by decreasing the pressure. These embodiments have the advantage that the gas produced using solar energy may be used for a longer period of time, also when solar energy is not available, for example during a part of nighttime. In some embodiments, no storage of carbon dioxide takes place. Preferably, the step of producing carbon dioxide using solar energy is not performed at least part of nighttime, more preferably it is not performed during substantially the whole nighttime. In a first variant, the step of producing a carbon dioxide stream using solar energy may comprise:providing a gas stream containing carbon dioxide;contacting the gas stream with a liquid solvent so that at least part of the carbon dioxide contained in the gas stream is absorbed by the liquid solvent, so as to provide a carbon dioxide-enriched solvent,heating the carbon dioxide-enriched solvent using solar energy so that at least part of the carbon dioxide contained in the dioxide-enriched solvent is separated from the solvent, so as to obtain a regenerated liquid solvent and the carbon dioxide stream. The gas stream containing carbon dioxide may be any type of gas stream. It may be a gas stream originating from a subterranean formation, preferably the subterranean formation in which gas is injected. Thus, carbon dioxide contained in the gas stream may be carbon dioxide naturally present in the reservoir and/or may be carbon dioxide which was injected into the subterranean formation. In this case, the method may comprise a step of processing the collected hydrocarbons so as to separate the gas stream containing carbon dioxide from liquid (including oil and water) and/or solids. The gas stream containing carbon dioxide may also be a flue gas stream originating from an electrical power plant, and preferably a fossil fuel power station such as a coal-fired power station or a gas-fired power station. The gas stream may also be a flue gas stream coming from a sulfur recovery unit (SRU). Indeed, in the underground reservoir, carbon dioxide is often associated with hydrogen sulfide (H2S), a poisonous gas. Therefore, gas released from the reservoir may be treated in an SRU to prevent hydrogen sulfide from being released to the ambient air. In an SRU, the sulfur recovery process is often based on a Claus process. In a first step of said Claus process, the hydrogen sulfide is partially burned with a combustive such as air or oxygen in a Claus furnace to form sulfur dioxide that will react, in a second step, with hydrogen sulfide to form elemental sulfur. The remaining H2S traces may be captured in a Tail Gas Treatment Unit (TGTU), positioned at the outlet of the Claus unit to significantly increase sulfur recovery. Depending on its origin, the gas stream containing carbon dioxide may comprise, in addition to carbon dioxide, nitrogen, methane, hydrogen sulfide, mercaptans . . . . The process of capturing carbon dioxide using solvents is well known by the skilled person. This process comprises a step of contacting the gas stream with a liquid solvent so that at least part of the carbon dioxide contained in the gas stream is absorbed by the liquid solvent. The liquid solvent preferably comprises or consists in an amine compound. Examples of amine compounds suitable for the invention are monoethanolamine (MEA), diethanolamine (DEA), methyldiethanolamine (MDEA), diisopropanolamine (DIPA), aminoethoxyethanol (Diglycolamine) and combinations thereof. Preferably, this step takes place in an absorber. Then, the carbon dioxide-enriched solvent is heated so that at least part of the carbon dioxide contained in the dioxide-enriched solvent is separated from the solvent. The solvent is thus regenerated, and a carbon dioxide stream may be recovered. The solvent regeneration usually takes place in a stripper (or desorber). In the present invention, the step of heating the carbon dioxide-enriched solvent so that at least part of the carbon dioxide contained in the dioxide-enriched solvent is separated from the solvent is preferably carried out using solar energy. In particular, solar thermal energy is advantageously used. Thermal energy to be used to separate carbon dioxide from the liquid solvent may be collected using one or more solar thermal collectors. The heat is then transferred to a working fluid that is used to heat the carbon dioxide-enriched solvent. Alternatively, solar photovoltaic energy may be used to heat solvent, for instance by resistive heating. Photovoltaic energy may be produced using one or more photovoltaic panels. Preferably, the carbon dioxide-enriched solvent is heated at a temperature of from 60 to 200° C., more preferably from 80 to 180° C. In a second variant, the step of producing a carbon dioxide stream using solar energy may comprise:providing a gas stream containing carbon dioxide,contacting the gas stream with a membrane so as to recover a carbon dioxide stream in the permeate, andcompressing the carbon dioxide stream using solar energy. The gas stream may be as described above. The process of capturing carbon dioxide using membranes is well known by the skilled person. The membrane may comprise or consist of materials such as zeolite, ceramic, polymer or silica. The compression step is preferably performed using one or more electrical compressor(s). Preferably, at least the compressor(s) is/are at least partially, preferably completely, powered by solar photovoltaic energy. Photovoltaic energy may be produced using one or more photovoltaic panels. Preferably, the photovoltaic panels are located close to the compressor(s). In a third variant, the step of producing a carbon dioxide stream using solar energy may comprise:providing a gas stream containing carbon dioxide,compressing the gas stream containing carbon dioxide using solar energy,cooling the compressed gas stream so that carbon dioxide liquefies and/or solidifies,separating liquid and/or solid carbon dioxide from gaseous light gases, so as to recover the carbon dioxide stream. In an alternative third variant, the step of producing a carbon dioxide stream using solar energy may comprise:providing a gas stream containing carbon dioxide,cooling the gas stream so that carbon dioxide liquefies and/or solidifies,separating liquid and/or solid carbon dioxide from gaseous light gases,compressing the liquid and/or solid carbon dioxide using solar energy, so as to recover the carbon dioxide stream. The gas stream may be as described above. The cryogenic CO2capture processes are well known by the skilled person. Preferably, the gas stream or compressed gas stream is cooled down to a temperature of from −100 to −150° C. The gas stream or compressed gas stream may be cooled in a heat exchanger, for example using a refrigerant comprising n-butane, propane, ethane, methane or mixtures thereof. The compression step is preferably performed using one or more electrical compressor(s). Preferably, at least the compressor(s) is/are at least partially, preferably completely, powered by solar photovoltaic energy. Photovoltaic energy may be produced using one or more photovoltaic panels. Preferably, the photovoltaic panels are located close to the compressor(s). At least a part of the produced gaseous light gas and/or a part of the produced carbon dioxide stream may be used in the heat exchanger to cool the gas stream or the compressed gas stream. The liquid and/or solid carbon dioxide or compressed liquid and/or solid carbon dioxide may be converted into gas or supercritical fluid. In the above described three variants, the remaining gases of the gas stream after carbon dioxide separation may be used in any known manner, for example by being injected into a subterranean formation, for example in the method of the invention, or may be released to the environment, optionally after being subjected to further treatments. In a fourth variant, the step of producing a carbon dioxide stream using solar energy may comprise:providing an air stream,separating at least part of the oxygen contained in the air stream from nitrogen so as to provide an oxygen stream,using the oxygen stream in a combustion reaction to produce a carbon dioxide stream. This variant uses an oxy-fuel combustion reaction. An oxy-fuel combustion reaction has the advantage of releasing pure, or essentially pure, carbon dioxide (vs. a mixture of carbon dioxide and nitrogen in the case where a combustion is carried out using air). Therefore, a carbon dioxide stream is directly recovered from the oxy-fuel combustion without needing to further separate carbon dioxide from other gases. The combustion (or oxy-fuel combustion) may be any kind of combustion. For example, the combustion may be carried out in an electrical power plant, and preferably a fossil fuel power station such as coal-fired power station or a gas-fired power station. The combustion may also be carried out in a sulfur recovery unit (SRU). The fuel used in the combustion reaction may be a fossil fuel such as natural gas, fuel oil, petroleum coke, or mixtures thereof. According to the invention, the step of separating at least part of the oxygen contained in the air stream from nitrogen so as to provide an oxygen stream is preferably performed using solar energy. The separation of oxygen from nitrogen may be carried out by a cryogenic fractional distillation process using solar energy, preferably solar photovoltaic energy. Solar energy may be collected and transferred as described above, such as by means of electrical compressors and/or photovoltaic panels. Nitrogen from which oxygen is separated may be used in any known manner, for example by being injected into a subterranean formation, for example in the method of the invention, or may be released to the environment, optionally after being subjected to further treatments. The above described four variants may be alternative variants or any combination thereof may be used in the method of the invention. Preferably, all process steps using solar energy, be it solar thermal energy and/or solar photovoltaic energy, described in the present description (in particular in the above four variants) are carried out during at least part of daytime. More preferably, they are not carried out during at least part of nighttime, even more preferably substantially the whole nighttime. In some embodiments, they are carried out during substantially the whole daytime. In some embodiments, no production of a carbon dioxide stream is implemented at least part of nighttime, for example during substantially the whole nighttime. In these embodiments, when no production of a carbon dioxide stream is performed, the gas stream containing carbon dioxide may be directly released to the ambient environment, in particular if it comes from an electrical power plant or an SRU, or more generally if it does not contain poisonous gases. If the gas stream originates from a subterranean formation, it may be treated in an SRU before being released. More particularly, if the gas stream contains hydrogen sulfide, it is preferably treated through an SRU, but if it contains no hydrogen sulfide, such an SRU treatment is not necessary. In some embodiments, the method may comprise a step of producing a carbon dioxide stream during at least a part of nighttime, for example during substantially the whole nighttime, using another energy than solar energy, for example fossil fuel energy. In particular, the method may comprise, during a period including the summer solstice, a step of producing a carbon dioxide stream during at least a part of daytime, for example during substantially the whole daytime, using solar energy, and a step of producing carbon dioxide during at least a part of nighttime, for example during substantially the whole nighttime, using another energy than solar energy such as fossil fuel energy. The method may also comprise no production of a carbon dioxide stream during a period including the winter solstice. | 34,519 |
11859478 | While embodiments of this disclosure have been depicted, such embodiments do not imply a limitation on the disclosure, and no such limitation should 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 not exhaustive of the scope of the disclosure. DESCRIPTION OF CERTAIN EMBODIMENTS The present disclosure relates to systems and methods for treating subterranean formations. More particularly, the present disclosure relates to fiber additives that may be useful as lost circulation materials in mitigating fluid loss and/or as diverting agents in subterranean treatment fluids such as drilling fluids. In order to overcome problems associated with lost circulation, lost-circulation materials (“LCM”) or fluid loss additives may be included in a wellbore fluid. LCMs may be swellable or non-swellable, granular-shaped or other geometric-shaped substances. As the wellbore fluid is placed into the well, the LCM may eliminate or lessen the amount of liquid or total fluid entering the subterranean formation. For example, the individual components of the LCM may build upon each other and form a bridge over highly-permeable areas of the formation, such as natural fissures, fractures, and vugular zones, or induced fractures. The bridge may eliminate or reduce the amount of liquid base fluid entering the formation via the wellbore. The present disclosure provides certain fiber additives for use as LCMs, fluid loss control agents, bridging agents, and/or diverting agents. The fiber additives may each include a fiber and calcium carbonate disposed on at least a portion of the outer surface of the fiber. The fiber additives of the present disclosure may be mixed with other components (e.g., a base fluid, other fluid loss additives or diverting agents, other additives, etc.) to form a treatment fluid that is then introduced into at least a portion of a subterranean formation to perform one or more operations therein. The calcium carbonate crystals disposed (e.g., grown) on the fibers may alter the physical properties of the fibers and thus enhance the efficiency of using the fibers as LCMs. For example, the calcium carbonate on the fibers according to the present disclosure may enhance the viscosity and/or gel strength of the wellbore fluid having the fiber additives. By growing calcium carbonate on the surface of fibers, it is possible to control the hydrophilicity of the resulting fiber additives by varying the coverage as well as morphology of the calcium carbonate. Further treatments may be performed on the fibers to modify the calcium carbonate hydrophilicity. Such treatments may include, for example, acidizing the fibers using a static acid. The use of calcium carbonate on fibers according to the present disclosure may improve the dispersity and compatibility of the fiber additives in drilling fluids for better application as LCMs. Among the many potential advantages to the methods and compositions of the present disclosure, only some of which are alluded to herein, the additives, methods, compositions, and systems of the present disclosure may provide improved sealing in pore throats or other areas of the formation, inter alia, because the fiber additives disclosed herein are more compatible with and/or dispersible in the base fluid than certain conventional fiber additives known in the art. As a result, smaller amounts of the fiber additives of the present disclosure may provide similar levels of fluid loss control as compared to conventional fiber LCMs. The disclosed fiber additives may act together to form a fiber network (or mesh) across larger pore throats or other areas of the formation that captures additional particles as well. The calcium carbonate added to the outer surface of the fibers may affect the fiber-to-fiber interactions such that the fibers are less likely to become aligned with each other when shear stresses act on the treatment fluid. As a result, the fiber additives may provide and maintain their configuration as a network plugging one or more fluid loss zones of the subterranean formation. The calcium carbonate crystals on the fibers modifies certain flow properties of the fiber additive suspension such as density and/or viscosity to enable better application as LCMs. Specifically, calcium carbonate on the fibers increases the density of the fibers, making them easier to mix with a base fluid (as they are less likely to float) to form the wellbore fluid. This increase in fiber density has been verified with sedimentation experiments using a Turbiscan® device, where the calcium carbonate coated fibers settle down in a base fluid faster than untreated fibers under the same conditions. The presence of calcium carbonate on the fiber also enhances the fiber's plug-in capability due to increases in the fiber stiffness and strength due to the increased density, and also may change the rheology of the fiber laden fluid. With the added calcium carbonate crystals, the fibers are no longer smooth. The less smooth surfaces of the fibers change the fiber to fiber interactions to increase the viscosity of the resulting wellbore fluid. In certain embodiments, the lost circulation material of the present disclosure may include a fiber. As used herein, the term “fiber” refers to a solid that is characterized by having a relatively high aspect ratio of length to diameter. For example, a fiber may have an aspect ratio of length to diameter of greater than about 2:1, or alternatively from about 2:1 to about 5,000:1, or alternatively from about 2:1 to about 1,000:1. The fiber may be natural, synthetic, biodegradable, and/or biocompatible. Examples of natural (or organic) fibers include, but are not limited to: fibers derived from an animal source such as silk, horse hair, or wool; fibers of cellulose including viscose cellulosic fibers, oil coated cellulosic fibers, and fibers derived from a plant product like paper fibers. Examples of synthetic fibers include, but are not limited to, polymers or copolymers composed of polypropylene, polyurethane, polyaramid, polyester, polyacrylonitrile, polyvinyl alcohol, and any copolymers, derivatives or combinations thereof. The term “derivative” includes any compound that is made from one of the listed compounds, for example, by replacing one atom in the listed compound with another atom or group of atoms, rearranging two or more atoms in the listed compound, ionizing one of the listed compounds, or creating a salt of one of the listed compounds. The term “derivative” also includes copolymers, terpolymers, and oligomers of the listed compound. Examples of biodegradable fibers include, but are not limited to, fibers composed of modified cellulose, chitosan, soya, modified chitosan, polycaprolactone, polylactic acid, poly(3-hydroxybutyrate), polyhydroxy-alkanoates, polyglycolic acid (PGA), polylactic acid (PLA), polyorthoesters, polycarbonates, polyaspartic acid, polyphosphoesters, and any copolymers, derivatives or combinations thereof. Examples of other suitable fibers include carbon fibers and melt-processed inorganic fibers including basalt fibers, wollastonite fibers, non-amorphous metallic fibers, ceramic fibers, and glass fibers. The fiber can also be a composite fiber made from any combination of the preceding materials. There can also be a mixture of fibers wherein the fibers are composed of different substances. A commercially-available example of suitable fibers is BAROLIFT® fibers (sweeping agent, available from Halliburton Energy Services, Inc.), which is a synthetic fiber. The fiber can have a fiber length and a fiber diameter. In certain embodiments, the fiber may have a length in the range of about 0.5 millimeters (mm) to about 25 mm, or alternatively about 1 mm to about 15 mm, or alternatively about 2 mm to about 10 mm. The fiber length may be specifically chosen based on an expected size of fractures or loss zones to which the fibers will be provided. At the time the fibers are initially formed or selected for use, the fibers may be much longer; the fibers may be cut to a desired length before deployment within a wellbore environment. In certain embodiments, the fiber may have a diameter in the range of about 0.5 microns (μm) to about 20 μm, or alternatively about 1 μm to about 15 μm, or alternatively about 5 μm to about 10 μm. Such fiber dimensions may be measured using the standard projection microscope method. In certain embodiments, the fiber additives may include fibrillated fibers. The term “fibrillated fibers” refers to fibers bearing sliver-like fibrils along the length of the fiber. The fibrils extend from the fiber, which may be referred to as the “core fiber,” and have a diameter significantly less than that of the core fiber from which the fibrils extend. The calcium carbonate disposed on the outer surface of the fiber may be distributed in any fashion or form (e.g., as a coating or film, or as distinct clusters or small masses of crystals), and may be disposed on the outer surface of the fiber in any amount. In some embodiments, the outer surface of the fiber may be at least partially coated with calcium carbonate, or may be substantially entirely or entirely coated with calcium carbonate. The calcium carbonate may be placed on the fiber by any suitable means of deposition. For example, in some embodiments, the calcium carbonate may be deposited on the fiber via various precipitation techniques. In certain such techniques, an aqueous solution of a calcium source (such as, e.g., a calcium chloride solution) and a carbonate source (such as, e.g., a sodium carbonate solution) may be mixed into a suspension of the base fibers to precipitate calcium carbonate on the fibers. This deposition method may create a variable layer of calcium carbonate crystals on the fibers. In other embodiments, calcium oxide (CaO, or lime) is hydrated into calcium hydroxide (Ca(OH)2, or slaked lime), followed by carbonation of the hydroxide in the presence of a suspension of the fibers. This deposition method, also known as a CO2precipitation of calcium carbonate (PCC) process, may create a relatively uniform, smooth coating of a thin layer of calcium carbonate on the fibers. Variations in the process of depositing calcium carbonate on the fibers may yield different sizes and/or morphologies of calcium carbonate crystals, as well as different coverages or concentrations of the calcium carbonate coating on the fibers. For example, the time and rate of precipitation of the calcium carbonate may be adjusted to provide a concentration or coverage of calcium carbonate within a desired range. The two calcium carbonate deposition methods discussed above may result in different crystal morphologies of the resultant precipitated calcium carbonate. Variations in temperature during the deposition process may change the morphology of the calcium carbonate deposited on the fibers. When the calcium carbonate is provided as a coating or layer on the outer surface of the fiber, such coating or film may have any suitable thickness, which may be uniform or variable across the outer surface of the fiber. For example, in some embodiments, the thickness of the calcium carbonate crystals may range from about 0.01 μm to about 10 μm, or alternatively about 0.05 μm to about 5 μm, or alternatively about 0.1 μm to about 1 μm, or alternatively about 0.2 μm to about 0.5 μm. Such crystal dimensions may be measured using the ASTM F1877 standard practice for characterization of particles. In embodiments where the calcium carbonate has a rod-shaped morphology (aragonite crystals), the thickness of the calcium carbonate crystals may be within any of the ranges listed above, while the length of the calcium carbonate crystals may range from about 1 μm to about 25 μm, or alternatively about 5 μm to about 20 μm, or alternatively about 10 μm to about 15 μm. Such crystal dimensions may be measured using the ASTM F1877 standard practice for characterization of particles. The calcium carbonate coating may have any suitable concentration within the resulting fiber additive to be used as lost circulation material. In some embodiments, the calcium carbonate may be present in the resulting fiber additive in an amount from about 1% to about 90% by weight of the fiber additive, from about 1% to about 75% by weight of the fiber additive, from about 1% to about 50% by weight of the fiber additive, or from about 10% to about 35% by weight of the fiber additive. A person of skill in the art with the benefit of this disclosure will recognize the appropriate crystal size (thickness and/or length) of the calcium carbonate crystals and appropriate concentration of the calcium carbonate suitable for a particular embodiment based on, for example, the desired density of the fiber additives, the desired viscosity of the resulting treatment fluid, and the like. The fiber additives of the present disclosure may include fibers of any size that is appropriate for use as a lost circulation material, a diverting agent, a bridging agent, a sweeping agent, a suspending agent, a filtration agent, or other fluid loss additive. In some embodiments, the fiber additives of the present disclosure may include fibers of substantially different lengths (e.g., a bimodal or multi-modal length distribution), among other reasons, to more effectively form a fiber network that will prevent a base fluid of the treatment fluid from penetrating into a subterranean formation. In certain embodiments, lost circulation materials formed by the disclosed fiber additives may have a bulk density of from about 0.05 grams per cubic centimeter (g/cc) to about 1 g/cc, alternatively from about 0.1 g/cc to about 0.5 g/cc, or alternatively from about 0.1 g/cc to about 0.2 g/cc, as measured using the ASTM D6683 standard test method for measuring bulk density. The treatment fluids used in the methods and systems of the present disclosure may include any base fluid known in the art, including aqueous base fluids, non-aqueous base fluids, and any combinations thereof. The term “base fluid” refers to the major component of the fluid (as opposed to components dissolved and/or suspended therein), and does not indicate any particular condition or property of that fluids such as its mass, amount, pH, etc. Aqueous fluids that may be suitable for use in the methods and systems of the present disclosure may include water from any source. Such aqueous fluids may include fresh water, salt water (e.g., water containing one or more salts dissolved therein), brine (e.g., saturated salt water), seawater, or any combination thereof. In most embodiments of the present disclosure, the aqueous fluids include one or more ionic species, such as those formed by salts dissolved in water. For example, seawater and/or produced water may include a variety of divalent cationic species dissolved therein. In certain embodiments, the density of the aqueous fluid can be adjusted, among other purposes, to provide additional particulate transport and suspension in the compositions of the present disclosure. In certain embodiments, the pH of the aqueous fluid may be adjusted (e.g., by a buffer or other pH adjusting agent) to a specific level, which may depend on, among other factors, the types of viscosifying agents, acids, and other additives included in the fluid. One of ordinary skill in the art, with the benefit of this disclosure, will recognize when such density and/or pH adjustments are appropriate. Examples of non-aqueous fluids that may be suitable for use in the methods and systems of the present disclosure include, but are not limited to, oils, hydrocarbons (e.g., diesel, mineral oil, or linear olefins and paraffins), organic liquids, and the like. In certain embodiments, the treatment fluids may include a mixture of one or more fluids and/or gases, including but not limited to emulsions (e.g., invert emulsions), foams, and the like. In certain embodiments, the density of the aqueous fluid can be adjusted, among other purposes, to provide additional particulate transport and suspension in the compositions of the present disclosure. In certain embodiments, the pH of the aqueous fluid may be adjusted (e.g., by a buffer or other pH adjusting agent) to a specific level, which may depend on, among other factors, the types of viscosifying agents, acids, and other additives included in the fluid. One of ordinary skill in the art, with the benefit of this disclosure, will recognize when such density and/or pH adjustments are appropriate. In an embodiment, the amount of base fluid present in the treatment fluid may be from about 50 to about 95 percent by weight (wt. %) of the treatment fluid, alternatively, from about 70 wt. % to about 90 wt. %, alternatively, from about 70 wt. % to about 85 wt. %. In some embodiments, the volume of a treatment fluid including a fiber additive lost circulation material that is introduced into a wellbore may depend, at least in part, on the bulk density of the lost circulation material. For example, the volume of a lost circulation fluid pill including a treatment fluid including a lost circulation material may depend, at least in part, on wellbore pressure and the bulk density of the lost circulation material. The amount of lost circulation material may be added to the drilling on a mass basis. The treatment fluid includes the disclosed fiber additives, which include a plurality of fibers with calcium carbonate thereon. In certain embodiments, the fiber additives may include other ingredients as well. In certain embodiments, the fiber additives may consist essentially of, or consist of, the plurality of fibers with calcium carbonate thereon. The fiber additives may be provided in dry form or in a liquid suspension. The fiber additives of the present disclosure may be included in a treatment fluid of the present disclosure in any amount suitable to form a fiber network that provides the desired amount of lost circulation prevention, fluid loss prevention, and/or diversion, either alone or in combination with other fluid loss additives or diverting agents in the fluid. In some embodiments, the calcium carbonate coated fiber additives of the present disclosure may be included in a treatment fluid in an amount of from about 1 pound per barrel of fluid (“lbs/bbl”) to about 30 lbs/bbl, or alternatively, from about 5 lbs/bbl to about 20 lbs/bbl, or alternatively, from about 10 lbs/bbl to about 15 lbs/bbl. This may be measured using a mud retort test in accordance with API recommended practice RP 13B-1. The amount of calcium carbonate coated fiber additives to include in a treatment fluid according to the present disclosure may vary depending on certain factors that will be apparent to those of skill in the art with the benefit of this disclosure, including but not limited to the severity of seepage losses occurring through the formation, porosity of the formation in which the treatment fluid will be used, the presence of other fluid loss additives or diverting agents in the fluid, pumpability limits, and the like. In some embodiments, the amounts/concentrations of the fiber additives of the present disclosure used may be less than the amounts/concentrations of conventional fiber lost circulation materials that would otherwise be necessary to provide the desired amount of lost circulation control. In certain embodiments, the treatment fluids used in the methods and systems of the present disclosure optionally may include any number of additional additives. Examples of such additional additives include, but are not limited to, salts, surfactants, acids, proppant particulates, diverting agents, gas, nitrogen, carbon dioxide, surface modifying agents, tackifying agents, foamers, corrosion inhibitors, scale inhibitors, catalysts, clay control agents, biocides, friction reducers, antifoam agents, bridging agents, flocculants, H2S scavengers, CO2scavengers, oxygen scavengers, lubricants, viscosifiers, breakers, weighting agents, relative permeability modifiers, resins, wetting agents, coating enhancement agents, filter cake removal agents, antifreeze agents (e.g., ethylene glycol), cross-linking agents, curing agents, gel time moderating agents, curing activators, and the like. In some embodiments, the treatment fluid may contain rheology (viscosity and gel strength) modifiers and stabilizers. A person skilled in the art, with the benefit of this disclosure, will recognize the types of additives that may be included in the fluids of the present disclosure for a particular application. In certain embodiments, the treatment fluids of the present disclosure may include additional lost circulation materials or bridging agents. In certain embodiments, additional lost circulation materials may include, but are not limited to, BARACARB® particulates (ground marble, available from Halliburton Energy Services, Inc.) including BARACARB® 5, BARACARB® 25, BARACARB® 150, BARACARB® 600, BARACARB® 1200; STEELSEAL® particulates (resilient graphitic carbon, available from Halliburton Energy Services, Inc.) including STEELSEAL® powder, STEELSEAL® 50, STEELSEAL® 150, STEELSEAL® 400 and STEELSEAL® 1000; WALL-NUT® particulates (ground walnut shells, available from Halliburton Energy Services, Inc.) including WALL-NUT® M, WALL-NUT® coarse, WALL-NUT® medium, and WALL-NUT® fine; BARAPLUG® (sized salt water, available from Halliburton Energy Services, Inc.) including BARAPLUG® 20, BARAPLUG® 50, and BARAPLUG® 3/300; BARAFLAKE® (calcium carbonate and polymers, available from Halliburton Energy Services, Inc.); and the like; and any combination thereof. In certain embodiments, the treatment fluids and lost circulation materials of the present disclosure may be effective over a range of pH levels. For example, in certain embodiments, the treatment fluids may provide effective loss zone treatment from a pH of about 7 to about 12. Additionally, the treatment fluids of the present disclosure may be suitable for a variety of subterranean formations, including, but not limited to shale formations and carbonate formations. In some embodiments, the treatment fluids of the present disclosure may have a density of from about 0.5 grams per cubic centimeter (g/cc) to about 3.0 g/cc, alternatively from about 0.8 g/cc to about 2.5 g/cc, alternatively from about 1.0 g/cc to about 2.0 g/cc, as measured using the ASTM D4380 standard test method for measuring density of a slurry via a mud balance. The treatment fluids of the present disclosure may be prepared using any suitable method and/or equipment (e.g., blenders, mixers, stirrers, etc.) known in the art at any time prior to their use. The treatment fluids may be prepared at least in part at a well site or at an offsite location. In certain embodiments, the fiber additives of the present disclosure and/or other components of the treatment fluid may be metered directly into a base treatment fluid to form a treatment fluid. In certain embodiments, the base fluid may be mixed with the fiber additives of the present disclosure and/or other components of the treatment fluid at a well site where the operation or treatment is conducted, either by batch mixing or continuous (“on-the-fly”) mixing. The term “on-the-fly” is used herein to include methods of combining two or more components wherein a flowing stream of one element is continuously introduced into a flowing stream of another component so that the streams are combined and mixed while continuing to flow as a single stream as part of the on-going treatment. Such mixing can also be described as “real-time” mixing. In other embodiments, the treatment fluids of the present disclosure may be prepared, either in whole or in part, at an offsite location and transported to the site where the treatment or operation is conducted. In introducing a treatment fluid of the present disclosure into a portion of a subterranean formation, the components of the treatment fluid may be mixed together at the surface and introduced into the formation together, or one or more components may be introduced into the formation at the surface separately from other components such that the components mix or intermingle in a portion of the formation to form a treatment fluid. In either such case, the treatment fluid is deemed to be introduced into at least a portion of the subterranean formation for purposes of the present disclosure. In certain embodiments, the treatment fluid may be introduced into at least a portion of the subterranean formation with the base fibers of the fiber additives, followed by the precipitation of calcium carbonate on the surface of the base fibers in situ. The term “base fibers” refers to the fibers in their uncoated state, i.e., before calcium carbonate is deposited on the fibers. The base fibers may be initially mixed into the treatment fluid and introduced downhole and into at least a portion of the subterranean formation. Then, additional fluids may be introduced downhole to cause the growth of calcium carbonate on the base fibers in the subterranean formation. For example, the additional fluids may include a solution containing metal oxides, followed by an injection of CO2downhole to precipitate calcium carbonate on the fibers. In other instances, the additional fluids may include an aqueous solution of a calcium source and a carbonate source that cause calcium carbonate crystals to form on the base fibers. Growing the calcium carbonate on the fibers in situ (as opposed to introducing the fiber additives with the calcium carbonate coating directly into the wellbore) may enable the base fibers to be deposited in fractures in a subterranean formation so that later calcium carbonate growth on the fibers increases the fracture stress. The present disclosure in some embodiments provides methods for using the treatment fluids to carry out a variety of subterranean treatments, including but not limited to, drilling operations, hydraulic fracturing treatments, and acidizing treatments. In some embodiments, the treatment fluids of the present disclosure may be used as a drilling fluid in drilling at least a portion of a wellbore to penetrate at least a portion of a subterranean formation. In certain embodiments, a treatment fluid may be introduced into a subterranean formation. In certain embodiments, the treatment fluid may be introduced into a wellbore that penetrates a subterranean formation. In some embodiments, the methods of the present disclosure may include introducing at least a portion of the treatment fluid within a loss zone or other flowpath through which the flow of fluids may be desirably reduced or ceased. In some embodiments, the treatment fluid may be introduced to the wellbore to prevent the loss of aqueous or non-aqueous fluids into loss zones such as voids, vugular zones, perforations, and natural or induced fractures. In some embodiments, the fiber additives of the present disclosure may be incorporated into a drilling fluid that is used in drilling at least a portion of a wellbore to penetrate at least a portion of the subterranean formation. As the drilling fluid is circulated in the wellbore during drilling, the fiber additives of the present disclosure (either alone or in combination with particulate additives) may form one or more fiber networks that at least partially obstruct spaces in the wellbore walls. The fiber additives may also provide enhanced cuttings transport in the circulated drilling fluid. In other embodiments, the fiber additives of the present disclosure may be incorporated into a relatively small volume of fluid (e.g., about 200 bbl or less) such as a drilling fluid or a viscosified gel that is introduced into a portion of a subterranean formation, e.g., a treatment pill such as a lost circulation pill, to mitigate or prevent the loss of fluid into a specific region of the formation (e.g., loss zones). In these embodiments, the fluid carrying the fiber additives of the present disclosure may be pumped to the specific region of interest, and the fiber additives of the present disclosure may be deposited in that region to form a fiber network that can at least partially close or seal off that region of the formation and divert the flow of fluids away from that region. After the fiber additives of the present disclosure have performed their function in reducing fluid loss and/or diverting fluids, in some embodiments, they may remain in the formation or may be removed from the formation through any suitable means. In some embodiments, the calcium carbonate portions of the fiber additives of the present disclosure may be dissolved using one or more acids. For example, an acidic solution may be introduced into the portion of the subterranean formation where the additives of the present disclosure have been placed. After dissolution of the calcium carbonate, in some embodiments, any remaining portions of the base fibers may be carried out of the formation, for example, with treatment fluids that are flowed back out of the formation, or the fibers may degrade in the formation over time. In certain embodiments, introduction of an acidic solution into the portion of the subterranean formation where the fiber additives have been placed may also dissolve the base fibers, particularly if the fibers are made from organic material, e.g., silk, cotton, paper, or animal hair. The methods and compositions of the present disclosure can be used in a variety of applications. These include downhole applications (e.g., drilling, fracturing, completions, oil production), use in conduits, containers, and/or other portions of refining applications, gas separation towers/applications, pipeline treatments, water disposal and/or treatments, and sewage disposal and/or treatments. In certain embodiments, a treatment fluid may be introduced into a subterranean formation. In some embodiments, the treatment fluid may be introduced into a wellbore that penetrates a subterranean formation. In certain embodiments, a wellbore may be drilled, and the treatment fluid may be circulated in the wellbore during, before, or after the drilling. In some embodiments, the treatment fluid may be introduced at a pressure sufficient to create or enhance one or more fractures within the subterranean formation (e.g., hydraulic fracturing). The fiber additives, fluids, and methods of the present disclosure may directly or indirectly affect one or more components or pieces of equipment associated with the preparation, delivery, recapture, recycling, reuse, and/or disposal of the compositions of the present disclosure. For example, the fiber additives, fluids, and methods may directly or indirectly affect one or more mixers, related mixing equipment, mud pits, storage facilities or units, composition separators, heat exchangers, sensors, gauges, pumps, compressors, and the like used generate, store, monitor, regulate, and/or recondition the compositions of the present disclosure. The fiber additives, fluids, and methods of the present disclosure may also directly or indirectly affect any transport or delivery equipment used to convey the fluid to a well site or downhole such as, for example, any transport vessels, conduits, pipelines, trucks, tubulars, and/or pipes used to compositionally move fluids from one location to another, any pumps, compressors, or motors (e.g., topside or downhole) used to drive the fluids into motion, any valves or related joints used to regulate the pressure or flow rate of the fluids, and any sensors (i.e., pressure and temperature), gauges, and/or combinations thereof, and the like. For example, and with reference toFIG.1, the disclosed additives and/or fluids may directly or indirectly affect one or more components or pieces of equipment associated with an example of a wellbore drilling assembly100, according to one or more embodiments. It should be noted that whileFIG.1generally depicts a land-based drilling assembly, those skilled in the art will readily recognize that the principles described herein are equally applicable to subsea drilling operations that employ floating or sea-based platforms and rigs, without departing from the scope of the disclosure. As illustrated, the drilling assembly100may include a drilling platform102that supports a derrick104having a traveling block106for raising and lowering a drill string108. The drill string108may include, but is not limited to, drill pipe and coiled tubing, as generally known to those skilled in the art. A kelly110supports the drill string108as it is lowered through a rotary table112. A drill bit114is attached to the distal end of the drill string108and is driven either by a downhole motor and/or via rotation of the drill string108from the well surface. As the bit114rotates, it creates a borehole116that penetrates various subterranean formations118. A pump120(e.g., a mud pump) circulates drilling fluid122through a feed pipe124and to the kelly110, which conveys the drilling fluid122downhole through the interior of the drill string108and through one or more orifices in the drill bit114. The drilling fluid122is then circulated back to the surface via an annulus126defined between the drill string108and the walls of the borehole116. At the surface, the recirculated or spent drilling fluid122exits the annulus126and may be conveyed to one or more fluid processing unit(s)128via an interconnecting flow line130. After passing through the fluid processing unit(s)128, a “cleaned” drilling fluid122is deposited into a nearby retention pit132(i.e., a mud pit). While illustrated as being arranged at the outlet of the wellbore116via the annulus126, those skilled in the art will readily appreciate that the fluid processing unit(s)128may be arranged at any other location in the drilling assembly100to facilitate its proper function, without departing from the scope of the disclosure. One or more of the disclosed fiber additives may be added to the drilling fluid122via a mixing hopper134communicably coupled to or otherwise in fluid communication with the retention pit132. The mixing hopper134may include, but is not limited to, mixers and related mixing equipment known to those skilled in the art. In other embodiments, however, the disclosed fiber additives may be added to the drilling fluid122at any other location in the drilling assembly100. In at least one embodiment, for example, there could be more than one retention pit132, such as multiple retention pits132in series. Moreover, the retention pit132may be representative of one or more fluid storage facilities and/or units where the disclosed fiber additives may be stored, reconditioned, and/or regulated until added to the drilling fluid122. As mentioned above, the disclosed fluids and/or fiber additives may directly or indirectly affect the components and equipment of the drilling assembly100. For example, the disclosed fluids and/or fiber additives may directly or indirectly affect the fluid processing unit(s)128which may include, but is not limited to, one or more of a shaker (e.g., shale shaker), a centrifuge, a hydrocyclone, a separator (including magnetic and electrical separators), a desilter, a desander, a separator, a filter (e.g., diatomaceous earth filters), a heat exchanger, any fluid reclamation equipment, and the like. The fluid processing unit(s)128may further include one or more sensors, gauges, pumps, compressors, and the like used to store, monitor, regulate, and/or recondition the disclosed fluids and/or fiber additives. The disclosed fluids and/or fiber additives may directly or indirectly affect the pump120, which representatively includes any conduits, pipelines, trucks, tubulars, and/or pipes used to fluidically convey the fluids and/or fiber additives downhole, any pumps, compressors, or motors (e.g., topside or downhole) used to drive the fluids and/or fiber additives into motion, any valves or related joints used to regulate the pressure or flow rate of the fluids and/or fiber additives, and any sensors (i.e., pressure, temperature, flow rate, etc.), gauges, and/or combinations thereof, and the like. The disclosed fluids and/or fiber additives may also directly or indirectly affect the mixing hopper134and the retention pit132and their assorted variations. The disclosed fluids and/or fiber additives may also directly or indirectly affect the various downhole equipment and tools that may come into contact with the fluids and/or fiber additives such as, but not limited to, the drill string108, any floats, drill collars, mud motors, downhole motors and/or pumps associated with the drill string108, and any MWD/LWD tools and related telemetry equipment, sensors or distributed sensors associated with the drill string108. The disclosed fluids and/or fiber additives may also directly or indirectly affect any downhole heat exchangers, valves and corresponding actuation devices, tool seals, packers and other wellbore isolation devices or components, and the like associated with the wellbore116. The disclosed fluids and/or fiber additives may also directly or indirectly affect the drill bit114, which may include, but is not limited to, roller cone bits, PDC bits, natural diamond bits, hole openers, reamers, coring bits, etc. While not specifically illustrated herein, the disclosed fluids and/or fiber additives may also directly or indirectly affect any transport or delivery equipment used to convey the fluids and/or fiber additives to the drilling assembly100such as, for example, any transport vessels, conduits, pipelines, trucks, tubulars, and/or pipes used to fluidically move the fluids and/or fiber additives from one location to another, any pumps, compressors, or motors used to drive the fluids and/or fiber additives into motion, any valves or related joints used to regulate the pressure or flow rate of the fluids and/or fiber additives, and any sensors (i.e., pressure and temperature), gauges, and/or combinations thereof, and the like. To facilitate a better understanding of the present disclosure, the following examples of certain aspects of preferred embodiments are given. The following examples are not the only examples that could be given according to the present disclosure and are not intended to limit the scope of the disclosure or claims. EXAMPLES The following examples use a series of fibers and calcium carbonate deposition processes to form fiber additives for use as lost circulation materials. Example 1 In this example, calcium carbonate crystallization (CaCO3) is used to deposit calcium carbonate on synthetic fibers. Calcium carbonate crystals were formed by mixing a CaCl2) solution and a NaCO3solution and adding the mixture to a suspension of BAROLIFT® fibers. The resulting precipitated calcium carbonate on the fibers was in the form of discrete calcite crystals that were sparsely distributed about the outer surface of the fibers. The shear thinning behavior of the resulting fiber additives was tested against that of untreated BAROLIFT® fibers. Both types of fibers were added to BARAZAN® D PLUS™ (viscosifier/suspension agent, available from Halliburton Energy Services, Inc.) in a concentration of 1.2 wt. %, and the shear viscosity for each solution was tested at different shear rates. The viscosity profile was obtained using a coaxial cylinder geometry (bob-cup) on an MCR501 rheometer (available from Anton Paar).FIG.2is a plot200illustrating the shear viscosity202in pascal seconds (Pa·s) of each of the tested fluids taken as a function of shear rate (1/seconds)204. A first trace206represents the measurements taken for the solution with untreated fibers, while a second trace208represents the measurements taken for the solution with the treated fibers (fibers with calcium carbonate grown thereon). As illustrated, the shear viscosity for the treated fibers208is higher than that for the untreated fibers206across a wide range of shear rates. These results indicate that the fiber additives with calcium carbonate coated thereon experience increased interactions between the fibers, thereby improving the shear thinning behavior of the suspension by preventing fiber alignment in shear. Example 2 In this example, calcium carbonate crystallization (CaCO3) is used to deposit calcium carbonate on synthetic fibers after an acid treatment is performed on the fibers. The acid treatment increases the population of calcium carbonate crystals formed on the outer surface of the fibers. A suspension of BAROLIFT® fibers was treated with 1M NaOH solution for 2 hours. Then, calcium carbonate crystals were formed on the fiber surface by mixing a CaCl2solution and a NaCO3solution and adding the mixture to the fibers. The resulting precipitated calcium carbonate on the fibers was in the form of discrete calcite crystals that were more concentrated on the outer surface of the fibers, as compared to the fiber additives of Example 1. Example 3 In this example, calcium carbonate crystallization (CaCO3) is used to deposit calcium carbonate on organic fibers. Calcium carbonate crystals were formed by mixing a CaCl2solution and a NaCO3solution and adding the mixture to a suspension of silk fibers, without any additional acid treatment. The resulting precipitated calcium carbonate on the fibers was more concentrated on the outer surface of the fibers, as compared to the fiber additives of both Examples 1 and 2. Example 4 In this example, C02-based precipitation of calcium carbonate (PCC) is used to deposit calcium carbonate on synthetic fibers. Calcium carbonate crystals were formed by adding Ca(OH)2to a suspension of BAROLIFT® fibers and flowing CO2through the mixture. The resulting precipitated calcium carbonate on the fibers was in the form of a relatively uniform coating of smaller crystals that were more evenly distributed about the fibers and having a better overall coverage of the fibers than any of the above Examples 1, 2, and 3. An embodiment of the present disclosure is a method including: providing a treatment fluid that includes a base fluid and a fiber additive that includes: a fiber and calcium carbonate disposed on at least a portion of an outer surface of the fiber; and introducing the treatment fluid into a wellbore penetrating at least a portion of a subterranean formation including a loss zone. In one or more embodiments described in the preceding paragraph, the method further includes at least partially plugging the loss zone by forming a fiber network across the loss zone via the fiber additive. In one or more embodiments described above, the fiber is an organic fiber. In one or more embodiments described above, the fiber is a synthetic fiber including a polymer. In one or more embodiments described above, the fiber has an aspect ratio of length to diameter of from about 2:1 to about 5,000:1. In one or more embodiments described above, the calcium carbonate has a thickness of about 0.01 μm to about 10 μm. In one or more embodiments described above, the calcium carbonate includes aragonite crystals having a length of about 1 μm to about 25 μm. In one or more embodiments described above, the fiber additive has a bulk density of about 0.05 g/cc to about 1 g/cc. In one or more embodiments described above, a plurality of fiber additives comprising the fiber additive are present in the treatment fluid in a concentration of about 1 lb/bbl to about 30 lbs/bbl. In one or more embodiments described above, the treatment fluid is a treatment pill having a volume of about 200 bbl or less. Another embodiment of the present disclosure is a method including: providing a treatment fluid that includes a base fluid and a plurality of fibers; introducing the treatment fluid into a wellbore penetrating at least a portion of a subterranean formation; and precipitating calcium carbonate on at least a portion of an outer surface of each of the plurality of fibers when the fibers are in the wellbore, the subterranean formation, or both. In one or more embodiments described in the preceding paragraph, growing the calcium carbonate includes: introducing additional fluids into the wellbore penetrating at least the portion of the subterranean formation; and precipitating the calcium carbonate on at least a portion of the outer surface of each of the fibers upon mixing the additional fluids with the plurality of fibers. In one or more embodiments described above, the method further includes: allowing the plurality of fibers to settle in one or more fractures in the subterranean formation; and upon growing the calcium carbonate on at least a portion of the outer surface of each of the plurality of fibers, increasing a fracture stress on the one or more fractures. In one or more embodiments described above, the method further includes at least partially plugging a loss zone in the subterranean formation by forming a fiber network across the loss zone via the fibers with calcium carbonate thereon. Another embodiment of the present disclosure is a composition including: a base fluid and a plurality of fiber additives, wherein each fiber additive includes a fiber and calcium carbonate disposed on at least a portion of an outer surface of the fiber. In one or more embodiments described in the preceding paragraph, the fiber is an organic fiber. In one or more embodiments described above, the fiber is a synthetic fiber including a polymer. In one or more embodiments described above, the fiber has a length of about 0.5 mm to about 25 mm, and a diameter of about 0.5 μm to about 20 μm. In one or more embodiments described above, the fiber lost circulation materials include a bulk density of about 0.05 g/cc to about 1 g/cc. In one or more embodiments described above, the fiber lost circulation materials are in the treatment fluid in a concentration of about 1 lb/bbl to about 30 lbs/bbl. 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. While numerous changes may be made by those skilled in the art, such changes are encompassed within the spirit of the subject matter defined by the appended claims. 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. In particular, every range of values (e.g., “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood as referring to the power set (the set of all subsets) of the respective range of values. The terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. | 47,543 |
11859479 | The embodiments of the present disclosure are detailed below with reference to the listed Figures. DETAILED DESCRIPTION OF THE EMBODIMENTS Before explaining the present disclosure in detail, it is to be understood that the disclosure is not limited to the specifics of particular embodiments as described and that it can be practiced, constructed, or carried out in various ways. While embodiments of the disclosure have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of the disclosure. The embodiments described herein are exemplary only, and are not intended to be limiting. Specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis of the claims and as a representative basis for teaching persons having ordinary skill in the art to variously employ the present embodiments. Many variations and modifications of embodiments disclosed herein are possible and are within the scope of the present disclosure. Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations. The use of the word “a” or “an” when used in conjunction with the term “comprising” in the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.” The word “about”, when referring to values, means plus or minus 5% of the stated number. The use of the term “optionally” with respect to any element of a claim is intended to mean that the subject element is required, or alternatively, is not required. Both alternatives are intended to be within the scope of the claim. Use of broader terms such as comprises, includes, having, etc. should be understood to provide support for narrower terms such as consisting of, consisting essentially of, comprised substantially of, and the like. When methods are disclosed or discussed, the order of the steps is not intended to be limiting, but merely exemplary unless otherwise stated. Accordingly, the scope of protection is not limited by the description herein, but is only limited by the claims which follow, encompassing all equivalents of the subject matter of the claims. Each and every claim is hereby incorporated into the specification as an embodiment of the present disclosure. Thus, the claims are a further description and are an addition to the embodiments of the present disclosure. The inclusion or discussion of a reference is not an admission that it is prior art to the present disclosure, especially any reference that may have a publication date after the priority date of this application. The disclosures of all patents, patent applications, and publications cited herein are hereby incorporated by reference, to the extent they provide background knowledge, or exemplary, procedural or other details supplementary to those set forth herein. The embodiments of the present disclosure generally relate to a computer implemented method for quantifying frac hits and accurately predicting oil and/or gas production rates for hydraulically fractured wells impacted by frac hits. The method of determining fracture interference in a hydraulically fractured well can have the steps of: providing a computer having a processor, a non-transitory data storage medium, and a transceiver, drilling a target well proximate to an existing well, fracturing the target well, flowing back the target well, measuring and collecting sensor data at the target well and the existing well, electronically communicating the sensor data to the compute, executing computer instructions stored within the non-transitory data storage medium instructing the processor to determine a degree of interference between the target well and the existing well, and transmitting the degree of interference to a display or a controller. The computer can be any computer known to persons having ordinary skill in the art capable of processing information and providing a result. The computer can have one or more processors in physical or network communication with a non-transitory data storage medium and a transceiver. The non-transitory data storage medium can be in physical or network communication with the processor and comprise computer instructions for instructing the processor to execute functions. The non-transitory computer readable medium can be a hard disk drive, solid state drive, flash drive, tape drive, and the like. The term “non-transitory computer readable medium” excludes any transitory signals but includes any non-transitory data storage circuitry, e.g., buffers, cache, and queues, within transceivers of transitory signals. The transceiver can be any device capable of receiving and transmitting electronic communications. Exemplary communications include ethernet, wireless, Bluetooth, LoRaWAN, and the like. The computer can transmit results to a display for action by a user, or directly to a controller to adjust well parameters. The target well, for the purposes of this disclosure, is the well of interest being drilled and fractured and the degree of interference with existing wells is quantified to predict production rates at the target well. The magnitude of interference in the proposed DPTA method will directly be related to the number and quality of the fracture interactions. Often a target well is drilled proximate an existing well. Spacing between wells can be five hundred feet, or even less, depending on the development plan, specific to the targeted reservoir, and available area for such development. When a well is fractured, primary fractures typically grow along the path of least resistance. When depleted or partially depleted wells exist nearby, the low-pressure areas surrounding the existing wells allow for the primary fractures to extend through them. As such, frac hits are almost inevitable during the fracturing process if nearby wells are heavily depleted. Therefore, controlling fracture growth from the target well, and properly managing pressure at existing wells, are primordial to avoid fracture-driven interactions from a completion design standpoint. Even so, newly created hydraulic fractures can still interact with fractures from existing wells through primary fractures (hydraulic fractures extending from the target well all the way to another well or directly into existing hydraulic fractures from the existing well), or secondary fractures (hydraulic fractures interacting with pre-existing and/or induced fracture networks around existing wells). After fracturing, the target well is flowed back, i.e., fracturing fluid is allowed to flow back to the surface in a controlled manner, after which oil and/or gas is produced at the well. While desirable to flow back at a constant rate, the method of the present disclosure can be applied when flowing at variable rates. Sensor readings are taken at the target well and the existing well and communicated to the computer. In embodiments, flow back rates can be controlled by executing computer instructions stored within the non-transitory data storage medium instructing the processor to output a signal to a controller. In embodiments, the existing well can be shut-in, i.e., capped to temporarily cease to produce oil and/or gas while pressure builds up, to flow at a theoretical constant production rate of zero. The existing well can also be pressurized to a desired pressure, for example to attain pressures significantly close to the original virgin reservoir pressure. Persons having ordinary skill in the art can determine ideal pressures for existing wells in order to provide the best application of the method of the present disclosure to the target well. In embodiments, machine learning and artificial intelligence can be employed to allow the computer to determine and control ideal pressures for existing wells by executing computer instructions stored within the non-transitory data storage medium instructing the processor to output a signal to a controller. A pressure differential between the target well and the existing well is calculated over a relatively short period of time by the processor by means of executing instructions stored in the non-transitory data storage medium. Various methods for determining pressure differential can be employed by persons having ordinary skill in the art to accomplish this task. The easiest method is to utilize direct readings from pressure transducers at each well. However, for example, knowing fluid density and flow rate or fluid velocity and wellbore design can result in the same data being calculated. The latter method is known as surface-to-sandface conversion. Persons having ordinary skill in the art can make use of the available data to calculate the pressure differential between the target well and the existing well(s) in any known manner. Pressure calculations need not be accomplished in the same manner at the target well and the existing well(s). Various sensors can be employed at the target well and existing well, such as to measure pressure, temperature, flow rate, fluid velocity, fluid density, and the like. Upon compiling sensor data at the target well and the existing well. An algorithm can be applied to the pressure differential data to model the degree of interference between the wells, and therefore determine the effect on oil and/or gas production by executing computer instructions stored within the non-transitory data storage medium instructing the processor. Each well is conceptualized as a tank. The frac hits are then modeled as a fluid connection between the tanks with a pipe fitting included. The pipe fitting can be any fitting that causes a pressure drop in fluid flow. Exemplary pipe fittings include valves, expanders, reducers, orifice plates, or any other fitting causing a pressure loss during fluid flow. By modeling a pipe fitting and comparing the data to collected sensor data, a quantified degree of interference, and therefore an effect on well production, can be determined within twenty days or less. Under ideal conditions, i.e. fluid expansion in the wellbore is negligible, the target well is flowed at a constant rate, existing wells are pressurized and shut in, and accurate sensor data is available, a quantified degree of interference can be determined in under five days. FIG.1Ashows a pressure profile at an existing well over time. The existing well is producing oil and/or gas in time periods A and B. Pressure is gradually dropping during period A and has reached the design operating bottom hole flowing pressure at period B. The existing well is shut-in in period C, allowing the pressure to build up. In time period C, the well may also be actively pressurized, which is known as preventive pre-loading. Time period D should exhibit a constant pressure behavior, if the offset well is to remain shut-in. If fracture interference with a target well is present, pressure will decline during time period D as shown by the dashed line. If the well is put back on stream during D, pressure declines in a similar manner as in time period A. Time period D is when sensor measurements would be needed to apply the method of the present disclosure. In time period E, the well is placed back into service. FIG.1Bshows a flow rate profile at the existing well ofFIG.1Aover time. The flow rate of the existing well rapidly increases in time period A and a relatively sharp decline follows through time periods A and B. The existing well, in this example, is shut-in during time period C. In embodiments, the existing well can be actively pressurized, or preloaded at this time. In time period D, the existing well remains shut-in and does not produce oil and/or gas. The dotted line in time periods C and D show what the expected rate of production decline would have been had the well not been shut-in. In time period E, the well is placed back into service. The solid line shows the expected flow or production rate. However, if there if fracture interference with a nearby well, the rate may be as shown by the dashed line. FIG.2Ashows a pressure profile at a target well over time. In this embodiment, after the existing well has been shut-in, the target well is fractured during time period C. The pressure fluctuates during the fracturing period which can induce some pressure changes in existing wells due to (1) stress shadowing effects (2) pressure communication through natural fractures, and/or (3) frac hits. Upon fracturing, the well can be flowed back at nearly constant rate during time period D. The expected pressure response is shown as a solid line. The pressure response shown as a dotted line represents the effect of fracture interference on pressure-transient behavior. This pressure difference, which can be positive or negative, is due to interference from the existing well. As the target well reaches its operating pressure in time period E, this pressure differential is still evident. FIG.2Bdepicts the rate history at the target well over time. Variations in flow rate during time period C are intended to represent hydraulic fracturing operations at the target well. When fracturing the job is finished, the well can be flowed back at nearly constant rate during time period D. Time period E shows the expected flow rate as a solid line, and the effect of fracture interference on flow rate as a dashed line. FIG.3illustrates a model as applied by the method of the present disclosure. Each well can be viewed as a tank with a fluid connection between. A valve is shown here as a pipe fitting. Depending on the degree of interference, pressure can bleed from (or to) Well A (existing well) to (or from) Well B (target well). The direction of flow leakage between wells is governed by the difference in their respective bottomhole pressure. For instance, Well A would see a gain in flow rate, or a delay in pressure decline, if this well is flowing at a higher rate than Well B, and vice versa. By taking sensor measurements and modeling valve aperture, the magnitude of interference can be properly estimated and production forecasts for each well can be adjusted accordingly. FIG.4illustrates an application of the method of the present disclosure. The set of solid curves represent the absolute difference in bottomhole pressure between Wells A and B divided by the sum of the individual flow rates. This parameter is referred to as rate-normalized pressure. The bottom set of curves show the logarithmic derivative of the rate-normalized pressure. Both set of curves are plotted for known degrees of interference. By matching actual sensor readings to these curves, a degree of interference can be calculated. This allows for the analogous pipe fitting model to be constructed. By applying a novel method of analyzing the differential pressures at the target and existing wells, and as can be seen from the log-log pressure-transient diagnostic plot, the method of the present disclosure can reach a result in a few days of readings, as opposed to existing rate-transient methods that need hundreds of days of production data. While the present disclosure emphasizes the presented embodiments and Figures, it should be understood that within the scope of the appended claims, the disclosure might be embodied other than as specifically enabled herein | 15,586 |
11859480 | DETAILED DESCRIPTION Both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the features, as claimed. As used herein, the terms “comprises,” “comprising,” “has,” “having,” “includes,” “including,” or other variations thereof, are intended to cover a non-exclusive inclusion such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements, but may include other elements not expressly listed or inherent to such a process, method, article, or apparatus. In this disclosure, unless stated otherwise, relative terms, such as, for example, “about,” “substantially,” and “approximately” are used to indicate a possible variation of ±10% in the stated value. FIG.1illustrates an exemplary hydraulic fracturing system2according to aspects of the disclosure. In particular,FIG.1depicts an exemplary site layout according to a well stimulation stage (e.g., hydraulic fracturing stage) of a drilling/mining process, such as after a well has been drilled at the site and the equipment used for drilling removed. The hydraulic fracturing system2may include fluid storage tanks4, sand storage tanks6, and blending equipment8for preparing a fracturing fluid. The fracturing fluid, which may, for example, include water, sand, and one or more chemicals, may be injected at pressure through one or more low pressure fluid lines34to one or more fracturing rigs10(FIG.1illustrates ten fracturing rigs10and two types of fracturing rigs—4 electric fracturing rigs10and6hydraulic fracturing rigs10). One or more types of fracturing rigs10may be used in connection with certain embodiments, such as mechanical fracturing rigs10, hydraulic fracturing rigs10, electric fracturing rigs10, and/or the like. The one or more fracturing rigs10may pump the fracturing fluid at high pressure to a well head18(FIG.1illustrates four well heads18) through one or more high-pressure fluid lines35. The one or more fracturing rigs10may be controlled by one or more rig controllers19(e.g., a rig controller19may receive, process, and/or provide to the fracturing rigs10a desired flow or pressure for a job). A bleed off tank (not shown inFIG.1) may be provided to receive bleed off liquid or gas from the fluid lines34and/or35(e.g., via one or more automatic pressure relief valves13). In addition, nitrogen, which may be beneficial to the hydraulic fracturing process for a variety of reasons, may be stored in tanks, with a pumping system (not shown inFIG.1) used to supply the nitrogen from the tanks to the fluid lines35or a well head18. In order to control flow of fluid, the hydraulic fracturing system2may include various types of valves. For example, the hydraulic fracturing system2may include one or more low pressure missile valves11upstream from the inlet of hydraulic fracturing pumps of the fracturing rigs10(e.g., an inlet of the low pressure missile valves11may be fluidly connected to fluid lines34and outlets of the low pressure missile valves11may be fluidly connected to the inlets of the hydraulic fracturing pumps). For example, the low pressure missile valves11may control fluid flow from fluid lines34to the hydraulic fracturing pumps of the fracturing rigs10. Additionally, or alternatively, the hydraulic fracturing system2may include one or more check valves15(e.g., actuated or one-way check valves15) that may be upstream from a fracturing tree being served by the fracturing rigs10(e.g., outlets of the pumps of the fracturing rigs10may be fluidly connected to inlets of the check valves15and outlets of the check valves15may be fluidly connected to inlet(s) of the fracturing tree). Additionally, or alternatively, the hydraulic fracturing system2may include one or more large bore valves12(e.g., on/off ball valves) of a grease system (FIG.1illustrates three large bore valves12). “Large bore” may refer to a line where flow is consolidated into one line and large bore valves12may shut the well off from missile lines. The hydraulic fracturing system2may include a system17that may gather data related to the hydraulic fracturing system2and may provide the data to the controller58for event correction and/or maintenance monitoring. For example, the controller58may track maintenance based on the data from the system17and may send a message to an operator or to the system17to grease the large bore valves12, e.g., after a certain number of cycles of opening/closing the large bore valves12. One or more other similar systems may be included in the hydraulic fracturing system2for monitoring operations of certain elements of the hydraulic fracturing system2and/or for taking corrective or maintenance-related actions. The large bore valves12may be downstream of outlets of the check valves15(e.g., inlets of the large bore valves12may be fluidly connected to outlets of the check valves15). Additionally, or alternatively, the hydraulic fracturing system2may include one or more automatic pressure relief valves13(FIG.1illustrates one automatic pressure relief valve13). For example, the automatic pressure relief valves13may be downstream of the one or more large bore valves12(e.g., inlets of the one or more automatic pressure relief valves13may be fluidly connected to outlets of the one or more large bore valves12). The automatic pressure relief valves13may be controlled and/or triggered automatically to release fluid pressure from fluid lines35. Additionally, or alternatively, the hydraulic fracturing system2may include one or more zipper valves14(FIG.1illustrates four zipper valves14) downstream of the automatic pressure relief valves13(e.g., outlets of the automatic pressure relief valves13may be fluidly connected to inlets of the zipper valves14). The zipper valves14may control fluid flow from fluid lines35to individual well heads18via zipper piping37(e.g., zipper piping may fluidly connect large bore valves12to the well heads18). The hydraulic fracturing system2may further include one or more well head valves16(FIG.1illustrates four well head valves16) downstream of the outlet of the zipper valves14(e.g., outlets of the zipper valves14may be fluidly connected to inlets of the well head valves16). The well head valves16may provide further fluid control to the well heads18from the fluid lines35. The hydraulic fracturing process performed at the site, using the hydraulic fracturing system2of the present disclosure, and the equipment used in the process, may be managed and/or monitored from a single location, such as a data monitoring system20, located at the site or at additional or alternative locations. According to an example, the data monitoring system20may be supported on a van, truck or may be otherwise mobile. As will be described below, the data monitoring system20may include a user device22for displaying or inputting data for monitoring performance and/or optimizing operation of the hydraulic fracturing system2and/or the fracturing rigs10. According to one embodiment, the data gathered by the data monitoring system20may be sent off-board or off-site for monitoring, recording, or reporting of performance of the hydraulic fracturing system2(or elements of the hydraulic fracturing system2) and/or for performing calculations related to the hydraulic fracturing system2. The data monitoring system20(or a controller of the data monitoring system20) may be communicatively connected to one or more controllers of the hydraulic fracturing system2that control subsystems of the hydraulic fracturing system2. For example, the data monitoring system20may be connected to the controllers via wired or wireless communication channels24The controllers may include a well head valve controller26connected to the one or more well head valves16and/or well heads18via a wired or wireless communication channel28. The well head valve controller26may be configured to actuate the one or more well head valves16and/or one or more mechanical components of the well heads18. Actuation of a valve or a well head18may include actuating one or more mechanical components to an open state, to a closed state, or to a partially closed or partially open state. Actuation, as described herein, may be performed by an associated actuator that may be integrated with the component to be actuated or may be a separate component (e.g., electric actuation of a valve may be performed through the use of an actuator integrated with a valve whereas hydraulic actuation may be performed through the use of an actuator located remote to the valve). Additionally, or alternatively, the controllers may include a zipper valve controller30connected to the one or more zipper valves14via a wired or wireless communication channel32. The zipper valve controller30may be configured to actuate the one or more zipper valves14. The controllers may, additionally, or alternatively, include a large bore valve controller36connected to the one or more large bore valves12via a wired or wireless communication channel38. The large bore valve controller36may be configured to actuate the one or more large bore valves12. The controllers may further include a valve controller40connected to the one or more low pressure missile valves11and/or the one or more check valves15via a wired or wireless communication channel42. The valve controller40may be configured to actuate the one or more low pressure missile valves11and/or the one or more check valves15. Additionally, or alternatively, the controllers may include a blender controller44connected to the blending equipment8via a wired or wireless communication channel46. The blender controller44may be configured to control operations of the blending equipment8(e.g., to control preparation of the fracturing fluid). The controllers may further include a power source controller48connected to various power sources (e.g., generators54, such as gaseous or blended generators54, energy storages55, such as batteries or fuel cells, and/or a utility power grid56) included in the hydraulic fracturing system2via a wired or wireless communication channel50. The generators54illustrated inFIG.1may be mobile generators54and may include turbine-based generators54or engine-based generators54. Other power sources may include renewable energy sources, such as solar cells, wind turbines, and/or the like from a micro-grid. The power source controller48may be configured to control one or more power sources and/or to control the provisioning of power from the power sources. For example, the power source controller48may power on or power off a generator54to meet power expectations, may switch one or more equipment of the hydraulic fracturing system2from consuming power from the utility power grid56to consuming power from one or more generators54and/or energy storages55(or vice versa), and/or the like. Fuel sources52may provide fuel (e.g., gas, compressed natural gas (CNG), hydrogen (H2), propane, field gas, diesel, etc.) to the mechanical fracturing rigs10. The provisioning of fuel to the fracturing rigs10may be controlled by a controller associated with the data monitoring system20and/or one or more other controllers associated with the fuel sources. Generators54may provide energy to fracturing rigs10. The provisioning of energy to the fracturing rigs10may be controlled by a controller associated with the data monitoring system20and/or one or more other controllers associated with the fuel sources. Elements of the hydraulic fracturing system2may be configured to operate in one or more operational modes. The one or more operational modes may include a manual mode where, for example, an operator programs desired operational parameters for elements of the hydraulic fracturing system2via the user device22and the operator ramps the hydraulic fracturing system2to the desired operational parameters via the user device22. In addition, in the manual mode, the operator may, via the user device22, approve or decline optimized operational parameters determined by the data monitoring system20according to certain embodiments described herein. Additionally, or alternatively, the one or more operational modes may include a semi-closed mode where, for example, the operator ramps the hydraulic fracturing system2to desired operational parameters via the user device22and a controller58may optimize the operation of the hydraulic fracturing system2based on operator input (e.g., fuel optimization, emissions optimization, total cost of ownership optimization, and/or the like). Additionally, or alternatively, the one or more operational modes may include a closed mode where, for example, the operator programs the desired operational parameters via the user device22, and one or more controllers (e.g., controller58and/or controllers64) ramp the operation of the hydraulic fracturing system2to the desired and/or optimized operational parameters. Additionally, or alternatively, the one or more operational modes may include an autonomous mode where, for example, the operator is remote to the data monitoring system20and/or a hydraulic fracturing site, and one or more controllers (e.g., controller58and/or controllers64) may monitor and control the operational parameters of the hydraulic fracturing system2automatically (e.g., automatically ramp operation of the hydraulic fracturing system2to desired operational parameters, determine and implement optimized operational parameters, etc.). The autonomous mode may additionally include operating in the closed mode with sub-controllers for valves of the hydraulic fracturing system2. Additionally, or alternatively, the one or more operational modes may include a multi-site mode where, for example, the operator can monitor and/or control operations of multiple hydraulic fracturing systems2at different sites. In some embodiments, the multi-site mode may include operating in the autonomous mode across multiple fracturing sites. Referring toFIG.2, the data monitoring system20may include the user device22and a controller58. The controller58may be provided, and may be part of, or may communicate with, the data monitoring system20. The controller58may reside in whole or in part at the data monitoring system20, or elsewhere relative to the hydraulic fracturing system2. The user device22and the controller58may be communicatively connected to each other via one or more wired or wireless connections for exchanging data, instructions, etc. Further, the controller58may be configured to communicate with one or more controllers64via wired or wireless communication channels. For example, the controller58may monitor and control, via the controllers64, various subsystems of the hydraulic fracturing system2. The controllers64may include the rig controller19, the well head valve controller26, the zipper valve controller30, the large bore valve controller36, the valve controller40, the blender controller44, and/or the power source controller48. The controllers64may be configured to communicate with one or more sensors (not shown inFIG.2) located on elements of the hydraulic fracturing system2. For example, the valve controller40may be configured to communicate with one or more sensors located at one or more valves, at components (e.g., an engine, a pump, etc.) of a fracturing rig10, etc. A sensor may be configured to detect or measure one or more physical properties related to operation and/or performance of the various elements of the hydraulic fracturing system2. For example, a sensor may be configured to provide a sensor signal indicative of a state of a valve (e.g., open, closed, a percentage open, or a percentage closed) to one or more of the controllers64, which may be configured to provide the sensor signal to the controller58. The controller58and/or the controllers64may include a processor and a memory (not illustrated inFIG.2). The processor may include a central processing unit (CPU), a graphics processing unit (GPU), a microprocessor, a digital signal processor and/or other processing units or components. Additionally, or alternatively, the functionality described herein can be performed, at least in part, by one or more hardware logic components. For example, and without limitation, illustrative types of hardware logic components that may be used include field-programmable gate arrays (FPGAs), application-specific integrated circuits (ASICs), application-specific standard products (ASSPs), system-on-a-chip systems (SOCs), complex programmable logic devices (CPLDs), etc. Additionally, the processor may possess its own local memory, which also may store program modules, program data, and/or one or more operating systems. The processor may include one or more cores. The memory may be a non-transitory computer-readable medium that may include volatile and/or nonvolatile memory, removable and/or non-removable media implemented in any method or technology for storage of information, such as computer-readable instructions, data structures, program modules, or other data. Such memory includes, but is not limited to, random access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other memory technology, compact disc read-only memory (CD-ROM), digital versatile discs (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, redundant array of independent disks (RAID) storage systems, or any other medium which can be used to store the desired information and which can be accessed by a computing device (e.g., the user device22, a server device, etc.). The memory may be implemented as computer-readable storage media (CRSM), which may be any available physical media accessible by the processor to execute instructions stored on the memory. The memory may have an operating system (OS) and/or a variety of suitable applications stored thereon. The OS, when executed by the processor, may enable management of hardware and/or software resources of the controller58and/or the controllers64. The memory may be capable of storing various computer readable instructions for performing certain operations described herein (e.g., operations of the controller58and/or the controllers64). The instructions, when executed by the processor and/or the hardware logic component, may cause certain operations described herein to be performed. The controller58may store and/or execute an optimization program60to optimize operations of the hydraulic fracturing system2(e.g., based on data stored in the memory or as otherwise provided to the controller58, such as via the user device22, gathered by the controllers64, or from a database). The controller58may store and/or execute a control logic program62(as described in more detail below with respect toFIG.4). Data used by the controller58may include site configuration-related information, scheduling-related information, cost-related information, emissions-related information, operation-related or state-related information, system operating parameters, and/or the like. However, various other additional or alternative data may be used. FIG.3is a diagram illustrating an exemplary optimization program60, according to aspects of the disclosure. As illustrated inFIG.3, the optimization program60may receive input data66and may use the input data66with an optimization algorithm76. For example, the optimization program60may receive the input data66from the user device22(e.g., a user may input the input data66via the user device22), from a server device, from a database, from memory of various equipment or components thereof of the hydraulic fracturing system2, and/or the like. The optimization program60may receive the input data66as a stream of data during operation of the hydraulic fracturing system2, prior to starting operations of the hydraulic fracturing system2, and/or the like. The input data66may be pre-determined and provided to the optimization program60(e.g., may be based on experimental or factory measurements of equipment), may be generated by the controller58(e.g., the controller58may broadcast a ping communication at a site in order to receive response pings from equipment at the site to determine which equipment is present, the controller58may measure, from sensor signals, the input data66, etc.), and/or the like. The input data66may include site configuration-related information68. For example, the site configuration-related information68may include numbers and/or types of elements of the hydraulic fracturing system2, powertrain types of the fracturing rigs10(e.g., mechanical or electric powertrain configurations), sub-types of mechanical powertrains (e.g., fuel types or levels of emission certified combustion engines), sub-types of electric powertrains (e.g., turbine generators, reciprocating engine generators, hydrogen fuel cells, energy storage systems, such as batteries, or direct-to-grid), possible operating modes of the elements of the hydraulic fracturing system2(e.g., an operator-based mode, a semi-closed mode, a closed mode, an autonomous mode, etc.), a maximum allowed pressure or flow rate of a fracturing rig10at the site, quantities and/or types of other equipment located at the site, ages, makes, models, and/or configurations of the equipment at the site, and/or the like. Additionally, or alternatively, the input data66may include scheduling-related information70. For example, the scheduling-related information70may include times, dates, durations, locations, etc. for certain operations of the hydraulic fracturing system2, such as scheduled times and dates for certain pump pressures, scheduled openings or closings of valves, etc. Additionally, or alternatively, the input data66may include cost-related information72. For example, the cost-related information72may include a cost of fuel or power for the hydraulic fracturing system2, a total cost of ownership of elements of the hydraulic fracturing system2(e.g., including maintenance costs, costs of fracturing fluid, or personnel costs), a cost of emissions (e.g., regulatory costs applied to emissions or costs related to reducing emissions, such as diesel exhaust fluid (DEF) costs), and/or the like. Additionally, or alternatively, the input data66may include emissions-related information74. For example, the emissions-related information74may include an amount of emissions from elements of the hydraulic fracturing system2(e.g., at different operating levels of the equipment), and/or the like. Additionally, or alternatively, the input data66may include equipment operation status information75. For example, the equipment operation status may include an operational mode of equipment of the hydraulic fracturing system2, such as for verification of requests to change the operational status of the equipment. The input data66may include various other types of data depending on the objective to be optimized by the optimization algorithm76. For example, the input data66may include transmission gear life predictions, pump cavitation predictions, pump life predictions, engine life predictions, and/or the like. As described in more detail herein, the optimization algorithm76may process the input data66after receiving the input data66. For example, the optimization algorithm76may process the input data66using a particle swarm algorithm78. The optimization algorithm76may then output optimized operational parameters80for the hydraulic fracturing system2to the user device22for viewing or modification, to the controller58and/or the controllers64to control operations of the hydraulic fracturing system2, and/or to a database for storage. Optimized operational parameters80may include, for example, values for engine power output, gear ratio, engine revolutions, throttle control, pump pressure, flow rate, or transmission speed optimized for emissions output, fuel consumption, lowest cost of operation, and/or the like. FIG.4is a diagram illustrating an exemplary control logic program62, according to aspects of the disclosure. As illustrated inFIG.4, the control logic program62may receive operation-related or state-related information82and may provide this information to control logic84. The operation-related or state-related information may include, for example, an operating pressure at a well head18or other elements of the hydraulic fracturing system2, an operating transmission gear or speed of the mechanical fracturing rigs10or power consumption of electric fracturing rigs10, a fuel or power consumption rate or elements of the hydraulic fracturing system2, a mixture of the fracturing fluid, whether certain types of elements or certain instances of certain types of elements are in operation, whether valves are opened or closed (or a degree to which they are opened or closed), and/or the like. The control logic program62may process the operation-related or state-related information82using control logic84. For example, the control logic84may be based on system operating parameters86, which may include operating limits, operating expectations, operating baselines, and/or the like for the hydraulic fracturing system2. The control logic84may then output control signals88based on the processing. For example, the control signals88may modify the operation of the hydraulic fracturing system2to avoid exceeding operating limits, to ramp operation of equipment to operating expectations, to ramp operation of equipment to exceed operating baselines, and/or the like. INDUSTRIAL APPLICABILITY The aspects of the controller58of the present disclosure and, in particular, the methods executed by the controller58may be used to assist in monitoring an operation or a state of one or more subsystems of a hydraulic fracturing system2and control fluid pressures at multiple well heads18for continuous pumping. Thus, certain aspects described herein may provide various advantages to the operation of the hydraulic fracturing system2, such as helping to ensure that pumping continues at a well during switching from one well head18to another well head18, which may help to prevent certain events, such as well collapse, from occurring during such a switch. In addition, the controller58may control the well heads18according to an operation schedule, which may improve safety at a fracturing site by reducing or eliminating a need for an operator to be present at the well heads18. Similarly, by automatically controlling the well head18according to an operation schedule, hydraulic fracturing operations can be more closely aligned to the intended schedule, which may reduce latency between stages of hydraulic fracturing operations, improve safety at a hydraulic fracturing site by reducing or eliminating implementation of incorrect fracturing operations due to deviations from the operation schedule, and/or the like. In addition, the controller58may monitor and control operations of multiple different well heads18at the same time (based on real-time or near real-time information), in a way very difficult or not possible through operator-based operation of the hydraulic fracturing system2. This may increase an efficiency of fracturing operation of the hydraulic fracturing system2. FIG.5illustrates a flowchart depicting an exemplary method100for monitoring and controlling fluid pressures of multiple well heads18, according to aspects of the disclosure. The method100illustrated inFIG.5may be implemented by the controller58. The steps of the method100described herein may be embodied as machine readable and executable software instructions, software code, or executable computer programs stored in a memory and executed by a processor of the controller58. The software instructions may be further embodied in one or more routines, subroutines, or modules and may utilize various auxiliary libraries and input/output functions to communicate with other equipment. The method100illustrated inFIG.5may also be associated with an operator interface (e.g., a human-machine interface, such as a graphical user interface (GUI)) through which an operator of the hydraulic fracturing system2may configure the optimization algorithm76and/or the control logic84, may select the input data66or the operation-related or state-related information82, may set objectives for the optimization algorithm76(e.g., objectives for the particle swarm algorithm78), and/or the like. Therefore, the method100may be implemented by the controller58to provide for continuous pumping. For example, the controller58may open the well head18-2and the zipper valves14-2, may start pumping to the well head18-2, and may then close the well-head18-1and the zipper valves14-1so that pumping is switched automatically from the well head18-1to the well head18-2without stopping the pumping. The controller58may determine a manner in which to control elements of the hydraulic fracturing system2for continuous pumping during a well head switch based on configurations (and limits) of the valves and/or well heads. This may prevent damage that might otherwise occur by continuing to pump while switching from one well head to another. Additionally, or alternatively, the controller58may close and open the well heads18-1and18-2automatically according to a schedule. At step102, the controller58may monitor, for two or more of multiple well heads18of a hydraulic fracturing system2, an operation or a state of one or more subsystems of the hydraulic fracturing system2. For example, the controller58may receive the operation-related or state-related information82as a stream of data, according to a schedule, etc. Additionally, or alternatively, the controller58may receive the operation-related or state-related information82from a sensor, from one or more of the controllers64, as input via the user device22, from a server device, and/or the like. In connection with the monitoring at step102, the controller58may additionally receive a configuration of the system operating parameters86via the user device22, from memory, from a server device, from a remote control center, and/or the like. A subsystem may include, for a certain well head18, particular equipment of the hydraulic fracturing system2associated with pumping fracturing fluid to the well head18. For example, the one or more subsystems may include the blending equipment8, certain fracturing rigs10(e.g., mechanical and/or electric fracturing rigs10), components of the fracturing rigs10(e.g., engines, pumps, transmissions, etc. for mechanical fracturing rigs10or variable frequency drives (VFDs) and electric motors for electric fracturing rigs10), certain low pressure missile valves11, certain large bore valves12, certain zipper valves14and/or zipper piping37and zipper valve14sets, the check valves15, certain well head valves16, the well head valve controller26, the zipper valve controller30, the large bore valve controller36, the valve controller40, the power source controller48, certain fuel sources52, the power sources, and/or the like. For example, a well head18may have dedicated valves, fracturing rigs10, and/or the like, and these may be the subsystems monitored for the well head18rather than monitoring all of the valves, fracturing rigs10, etc. of the hydraulic fracturing system2. This may conserve computing resources of the controller58by reducing an amount of information that the controller58has to process. In some embodiments, the operation or the state of the one or more subsystems may be monitored for multiple well heads18at the same time. For example,FIG.1illustrates the hydraulic fracturing system2as including four well heads18. In this example, the controller58may monitor the operation or the state of a first fracturing rig10, a first missile valve11, a first large bore valve12, a first zipper valve14, and a first well head valve16for a first well head18, may monitor the operation or the state of a second fracturing rig10, a second missile valve11, a second large bore valve12, a second zipper valve14, and a second well head valve16for a second well head18, and so forth. At step104, the controller58may control, based on an operation schedule for the hydraulic fracturing system and based on monitoring the operation or the state, fluid pressures at the two or more well heads for continuous pumping. For example, the controlling may include starting pumping at a first well head18then starting simultaneous pumping at a second well head18. After the pumping is started at the second well head18, the pumping is stopped at the first well head18. This usage of simultaneous pumping at multiple well heads18may prevent flow from stopping to a well while fluid flow is switched from the first well head18to the second well head18. Starting or stopping pumping at a well head18may include starting or stopping the one or more subsystems associated with the well head18. For example, blending equipment8and a fracturing rig10may be started or stopped, various valves may be opened to start pumping to the well head18or closed to stop the pumping, and/or the like. In some embodiments, the controller58may determine to switch the flow between well heads18based on the monitoring. For example, the controller58may control the well heads18automatically based on determining that pumping through a first well head18is not meeting operating expectations or is exceeding operating limits (e.g., pressure limits, time limits, etc.), where the failure to meet operating expectations or the exceeding of operating limits may indicate that the pumping is to be switched from the first well head18to the second well head18. In performing these determinations, the controller58may process the information received at step102using the control logic84to determine whether operational limits have been exceeded, whether the equipment of the hydraulic fracturing system2are operating at least at minimum operating baselines or within expected ranges, etc. For example, the controller58may perform a comparison of the operation-related or state-related information82to system operating parameters86and may determine that the fluid pressure at the well head18is not meeting expectations or is beyond operating limits. The controller58may then determine to switch from the first well head18to the second well head18based on a result of processing using the control logic84. The controller58may then provide control signals88to the controllers64and/or directly to equipment of the hydraulic fracturing system2to implement the continuous pumping. For example, the controller58may provide control signals88to start blending equipment8and/or fracturing rigs10, to open valves at a second well head18, to close valves at a first well head18, to stop blending equipment8and/or fracturing rigs10, and/or the like. Additionally, or alternatively, the controller58may output operational parameters (or instructions for modifying operational parameters) to the controllers64, and the controllers64may generate the control signals88. In certain embodiments, the operational parameters output from the controller58may include optimized operational parameters80(e.g., the controller58may perform the optimization algorithm76prior to outputting the control signals88, as described in more detail elsewhere herein). The operation schedule may include days, times, durations, etc. for operation of the well head18and corresponding fluid pressures for the various different days, times, durations, etc. (e.g., for a planned well completion). When controlling the fluid pressure, the controller58may process the operation schedule to determine whether the fluid pressure needs to be modified, to determine optimized operational parameters for achieving a fluid pressure (or preventing a pressure limit from being exceeded), and/or the like. For example, the controller58may process the operation schedule to determine whether the fluid pressure at the well head18matches a scheduled fluid pressure, whether to increase or decrease the fluid pressure based on an amount of time that the fracturing operations have been performed at a site, and/or the like. This may facilitate continuous operation of hydraulic fracturing operations, pre-scheduling of control signals88, and/or the like in a manner very difficult or not possible with operator-controlled hydraulic fracturing operations, which may increase an efficiency of hydraulic fracturing operations of the hydraulic fracturing system2. In connection with the steps102and104, the controller58may monitor information including an open or closed state of various valves of the hydraulic fracturing system2, and may control the valves to start pumping at one well head18while pumping is occurring at another well head18. For example, the controller58may generate control signals88to actuate mechanical components of the valves to adjust the degree to which the valves are opened or closed. Additionally, or alternatively, in connection with the steps102and104, the controller58may perform similar monitoring and controlling for blending equipment8and/or fracturing rigs10to implement the continuous pumping. For example, the controller58may generate control signals88to start a set of equipment for pumping to a second well head18while pumping to a first well head18. Additionally, or alternatively, in connection with the steps at102and104, the controller58may monitor fluid pressure at the well heads18during switching of flow from one well head18to another well head18. For example, the controller58may monitor information including an open or closed state of various valves of the hydraulic fracturing system2, and may control the valves to prevent falling below a minimum suction pressure or from going lower than the low pressure limit at any of the well heads18. As a specific example, the controller58may generate control signals88to actuate mechanical components of the valves to adjust the degree to which the valves are opened or closed based on increases or decreases in the fluid pressures. As another example, the controller58may monitor and control the blending equipment8to prevent the hydraulic fracturing system2from exceeding the pressure limit while pumping to multiple well heads18at the same time. For example, the controller58may generate control signals88to adjust a mixture of the fracturing fluid, an output flow rate of the blending equipment8, and/or the like. Additionally, or alternatively, in connection with the steps102and104, the controller58may monitor and control pumps of the fracturing rigs10. For example, the controller58may monitor an output pressure or flow rate of the pumps (e.g., alone or in connection with pressures at the valves of the hydraulic fracturing system2) and may generate control signals88to increase or decrease a flow rates or pressures from the pumps based on detected downstream pressures at the well heads18. As another example, the controller58may monitor and control one or more subsystems within safety limits for fluid pressure during the continuous pumping. For example, the controller58may, when the controller58detects that an operational parameter has exceeded a safety limit or is within a threshold percentage of the safety limit for the fluid pressure, generate control signals88to increase or decrease certain operational parameters related to the safety limit, to cause a hard stop of certain equipment of the hydraulic fracturing system2, and/or the like. Although the method100illustrated inFIG.5is described as including steps102and104, the method100may not include all of these steps or may include additional or different steps. For example, the controller58may determine which equipment, components of the equipment, etc. are causing an issue during well head18switching based on processing operation-related or state-related information82using the control logic84. As a specific example, if the controller58determines that the fluid pressure at a well head18is exceeding a pressure limit during switching well heads18and additionally determines that one or more zipper valves14are closed to a greater amount than expected, the controller58may determine that the excessively closed zipper valves14are the cause of the excess fluid pressure. The controller58may, based on the monitoring the operation or the state of one or more subsystems, control the one or more subsystems within operating limits or based on operating expectations to cause or prevent an occurrence of one or more events. The one or more events may be related to well integrity during hydraulic fracturing operations. For example, the one or more events to be caused may include a well pressure meeting or maintaining a minimum well pressure, the well pressure being within a range of pressure values, an operation speed (e.g., transmission speed) of the one or more subsystems meeting or maintaining a minimum operation speed, the operation speed being within a range of speed values, and/or the like. Additionally, or alternatively, for example, the one or more events to be prevented may include the well pressure exceeding a pressure limit, a well collapse, stalling of the one or more subsystems, a deviation from a fracturing schedule, and/or the like. Additionally, or alternatively, certain embodiments may prevent cavitation on a low pressure line due to blender equipment8not providing enough pressure. For example, controller58may send an instruction to ramp down the pump experiencing cavitation and ramping up one or more other pumps to compensate for the ramped-down pumps. Additionally, or alternatively, certain embodiments may control operational efficiency to prevent loss of fuel by controlling fuel pressure, prevent loss of blending by controlling gas pressure, and/or the like. Additionally, or alternatively, certain embodiments may prevent operational interruption of an electric fracturing rig10by preventing loss of power or voltage, preventing start up of an electric fracturing rig10before a power source is ready (e.g., by checking power prior to ramping), and/or the like. Additionally, or alternatively, the method100may include optimizing operation of one or more subsystems of the hydraulic fracturing system2using a particle swarm algorithm or another type of optimization algorithm. For example, a particle swarm algorithm may iteratively tune operational parameters to search for a set of optimized operational parameters80(P1, P2, . . . Pn) that achieve an optimization objective. In this way, “optimized,” “optimization” and similar terms used herein may refer to a selection of values (for operational parameters) based on some criteria (an objective) from a set of available values. An objective may be of any suitable type, such as minimizing the cost of fracturing operations of the hydraulic fracturing system2, minimizing fuel or power consumption of the hydraulic fracturing system2, minimizing emissions from the hydraulic fracturing system2, maximizing an operational life of equipment of the hydraulic fracturing system2, minimizing an overall time of the hydraulic fracturing operations, minimizing a cost of ownership of equipment used in the hydraulic fracturing operation, maximizing a maintenance interval of equipment of the hydraulic fracturing system2, and/or any combinations thereof. In addition, and as another example, the method100may further include outputting optimized operational parameters80. For example, the controller58may output the optimized operational parameters80to one or more destinations for display (e.g., for approval and/or modification by an operator), storage (e.g., for historical comparison or analysis, for later usage, etc.), inclusion into control signals (e.g., control signals88that cause elements of the hydraulic fracturing system2to operate according to the optimized operational parameters80), and/or the like. With respect to inclusion in control signals88, the controller58may use a processor to generate control signals88and may output the control signals88to a controller64or to equipment of the hydraulic fracturing system2using a transceiver (or a transmitter) to cause the equipment to operate in a particular manner. In this way, the controller58may conserve equipment life, fuel, emissions, power, etc. of the hydraulic fracturing system2. Through optimization of an objective, and generation of corresponding control signals88for equipment, certain embodiments may conserve resources (e.g., operational life, power resources, fuel resources, etc.) associated with the hydraulic fracturing system2and may facilitate improvements in a site or system-level efficiency of the hydraulic fracturing system2. Site or system-level optimization may facilitate further gains in efficiency and conservation of resources compared to optimization of individual equipment through consideration of ways in which certain equipment operations affect site-level or system-level objectives. For example, if the objective for the hydraulic fracturing system2is to reduce fuel consumption and emissions below a threshold while maintaining a fluid pressure and an operation schedule, the controller58may determine that modifying any of the operation of various blending equipment8and the operation of various fracturing rigs10can reduce the fuel consumption and the emissions to a suitable level, but that just modifying the operation of the blending equipment8will keep the hydraulic fracturing operations on schedule. The one or more destinations may include the user device22(or a display of the user device22), a server device, a controller, a database, memory, etc. In this way, the controller58of certain embodiments can provide real-time (or near real-time) monitoring and controlling of fluid pressures at two or more well heads18for continuous pumping based on an operation schedule. This may improve operation of a hydraulic fracturing system2from a site-level perspective by facilitating automatic control of the switching of well heads18, which may improve an efficiency of the operations. In addition, certain embodiments described herein may increase safety at a hydraulic fracturing system2by providing for faster responses to triggers for switching well heads18, by reducing or eliminating a need for human operators to be physically present at the well heads18, and/or the like. Furthermore, certain embodiments may reduce or eliminate latency between stages of hydraulic fracturing operations through operation schedule-based control, which may improve an efficiency of the hydraulic fracturing system2, conserve fuel or power resources by reducing an amount of time needed to perform hydraulic fracturing operations, and/or the like. It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed system without departing from the scope of the disclosure. Other embodiments of the system will be apparent to those skilled in the art from consideration of the specification and practice of the system disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims and their equivalents. | 47,389 |
11859481 | DETAILED DESCRIPTION In order to make objects, technical solutions, and advantages of the embodiments of the present disclosure apparent, the technical solutions of the embodiments of the present disclosure will be described in a clearly and fully understandable way in connection with the drawings related to the embodiments of the present disclosure. Apparently, the described embodiments are just a part but not all of the embodiments of the present disclosure. Based on the described embodiments of the present disclosure, those skilled in the art can obtain other embodiment(s), without any inventive work, which should be within the scope of the present disclosure. Unless otherwise defined, all the technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art to which the present disclosure belongs. The terms “first,” “second,” etc., which are used in the present disclosure, are not intended to indicate any sequence, amount or importance, but distinguish various components. The terms “comprise,” “comprising,” “include,” “including,” etc., are intended to specify that the elements or the objects stated before these terms encompass the elements or the objects and equivalents thereof listed after these terms, but do not preclude the other elements or objects. In research, the inventors of the present application have found that there is no effective silencing device at the outer side of the power device (for example, including the driving machine and other devices) and the plunger pump in a common fracturing apparatus, that is, there is no good noise reduction device, so most apparatuses fail to meet the requirements of the oil and gas industry standard SY/T 7086. When a fracturing apparatus works with rated power, it is easy to generate high noise, which will lead to serious noise pollution during well site operation. The embodiments of the present disclosure provide a fracturing apparatus, which includes a plunger pump, a transmission shaft, a main motor, an oil pipe, a first radiator and a noise reduction cabin. The main motor is spaced apart from the plunger pump, and the plunger pump is connected with the main motor through the transmission shaft; the oil pipe is connected with the plunger pump; the first radiator is spaced apart from the plunger pump, and the first radiator is configured to dissipate heat from oil in the oil pipe; at least part of the oil pipe, the main motor and the first radiator are all located at the inner side of the noise reduction cabin, and the plunger pump is located at the outer side of the noise reduction cabin. The noise reduction cabin provided in the fracturing apparatus can separate structures, such as the main motor and the first radiator, etc., from the plunger pump, which can not only reduce the noise generated by the structures, such as the main motor and the first radiator, etc., and reduce the interference between electrical components, but also reduce the risk that the structures, such as the main motor and the first radiator, etc., are damaged by high-pressure liquid. The fracturing apparatus provided by the embodiments of the present disclosure will be described below with reference to the accompanying drawings. FIG.1is a side view of a partial structure of a fracturing apparatus according to an embodiment of the present disclosure.FIG.2is a schematic diagram of a partial structure of a fracturing apparatus according to an embodiment of the present disclosure, andFIG.3is a schematic diagram of a noise reduction cabin and some devices in the noise reduction cabin of the fracturing apparatus shown inFIG.1. For example, in order to more clearly show each part of the noise reduction cabin, some cabin side walls or cabin doors of the noise reduction cabins shown inFIGS.1and3are omitted, and the overall appearance of the noise reduction cabin can refer toFIG.4described later. As shown inFIGS.1-3, the fracturing apparatus includes a plunger pump110, a transmission shaft120and a main motor200, and the main motor200is spaced apart from the plunger pump110. For example, there is a certain distance between the main motor200and the plunger pump110. For example, the main motor200can be an electric motor, the plunger pump110is connected with the main motor200through the transmission shaft120, and the main motor200is configured to drive the plunger pump110to work through the transmission shaft120. For example, the transmission shaft120is located between the plunger pump110and the main motor200. For example, the plunger pump110includes a power end and a fluid end. The plunger reciprocates in the pump head body (valve box), which causes the change of the sealing volume in the pump head body to convey the fluid. For example, the power end includes a pump housing, a crankshaft and a crosshead assembly, etc., and is configured to reduce the rotating speed, to increase the torque, and to convert the rotating motion into reciprocating motion. For example, the fluid end includes a pump head body, a plunger and a valve, etc., and is configured to convert mechanical energy into fluid energy. For example, the main motor200is connected to the power end of the plunger pump110and is configured to provide power to the power end of the plunger pump110. As shown inFIGS.1-3, the fracturing apparatus further includes an oil pipe130which is configured to be connected with the plunger pump110. For example, the oil pipe130is configured to transmit lubricating oil, and the lubricating oil is configured to lubricate components in the power end of the plunger pump110. For example, the fracturing apparatus further includes a lubricating motor150and a lubricating pump, the oil pipe130is connected with the lubricating pump, the lubricating motor150provides power to the lubricating pump to drive the lubricating pump to run. After the lubricating pump runs, the lubricating oil flows into the oil pipe130. After flowing through the power end of the plunger pump110, the lubricating oil in the oil pipe130will return to the lubricating oil tank. For example, the lubricating pump can be immersed in the lubricating oil in the lubricating oil tank. As shown inFIGS.1-3, the fracturing apparatus further includes a first radiator300spaced apart from the plunger pump110, and the first radiator300is configured to dissipate heat from the oil in the oil pipe130. For example, the first radiator300can be a lubricating oil radiator configured to dissipate heat from the lubricating oil in the oil pipe130. For example, the first radiator300can include a heat dissipation pipe310, the heat dissipation pipe310includes an oil inlet and an oil outlet, and the oil inlet and the oil outlet are respectively connected with the oil pipe130. The lubricating oil transmitted in the oil pipe130flows into the heat dissipation pipe310through the oil inlet of the heat dissipation pipe310, and then flows into the oil pipe130from the oil outlet of the heat dissipation pipe310after heat dissipation through the heat dissipation pipe310. For example, the first radiator300can be located on the oil inlet pipeline of the plunger pump110or on the oil outlet pipeline of the plunger pump110. As shown inFIGS.1-3, the fracturing apparatus further includes a noise reduction cabin400, and the main motor200, the first radiator300and at least part of the oil pipe130are located at the inner side of the noise reduction cabin400, and the plunger pump110is located at the outer side of the noise reduction cabin400. The plunger pump will produce a high pressure of nearly 15000 Psi in the working process. Once the high-pressure liquid leaks, it will produce great destructive power. The fracturing apparatus provided by the present disclosure is provided with a noise reduction cabin, which can separate structures, such as the main motor and the first radiator, etc., from the plunger pump, thus not only reducing the noise generated by the structures, such as the main motor and the first radiator, etc., and reducing the interference between electrical components, but also reducing the risk that the structures, such as the main motor and the first radiator, etc., are damaged by high-pressure liquid. For example, as shown inFIGS.1-3, the noise reduction cabin400includes at least one cabin side wall440. For example, one cabin side wall440is arranged between the main motor200and the plunger pump110, and the cabin side wall440can be provided with an opening, the transmission shaft120passes through the opening to connect with the main motor200. For example, a flange201is provided at the opening for connection with the transmission shaft120. For example, as shown inFIGS.1-3, the lubricating motor150is located in the noise reduction cabin400. The noise reduction cabin400can not only reduce the noise of the lubricating motor150, but also reduce the risk of the lubricating motor150being damaged by high-pressure liquid. For example, as shown inFIGS.1-3, the fracturing apparatus further includes a platform500, and the plunger pump110, the main motor200and the noise reduction cabin400are all located on the supporting surface of the platform500. For example, the platform500can be a skid-mounted platform. For example, the supporting surface can be a plane perpendicular to the Y direction shown inFIG.1. The supporting surface is defined as such a plane to better illustrate the positional relationship between other structures and the plane where the supporting surface is located, but it does not mean that the surface of the platform facing the main motor must be a plane. For example, in the case where the surface of the platform has convex structures, the supporting surface as a plane can be a plane located at the bottom of these convex structures or a plane passing through a point on the surface of the platform. In the direction perpendicular to the supporting surface, the direction from the opposite side of the supporting surface of the platform to the supporting surface is called the upward direction (that is, the direction indicated by the arrow in the X direction), and the direction from the supporting surface to the opposite side of the supporting surface of the platform is called the downward direction. In the direction parallel to the supporting surface, the direction from the edge of the noise reduction cabin to the center of the noise reduction cabin is called the inward direction, and the direction from the center of the noise reduction cabin to the edge of the noise reduction cabin is called the outward direction. Therefore, the relative positional relationships indicated by “inner” and “outer” also have a clear meaning. For example, as shown inFIGS.1-3, the noise reduction cabin400includes an air inlet410and an air outlet420, and the distance between the air outlet420and the supporting surface of the platform500is greater than the distance between the air inlet410and the supporting surface. For example, the air outlet420is located on the upper side of the air inlet410. The distance between the air outlet and the supporting surface can indicate the distance between the end or surface of the air outlet closest to the supporting surface and the supporting surface, and the distance between the air inlet and the supporting surface can indicate the distance between the end or surface of the air inlet closest to the supporting surface and the supporting surface. By arranging the air outlet on the upper side of the air inlet, the air in the external environment can blow through the components, such as the main motor and the first radiator, etc., during the process of spreading upward (to the air outlet) from the air inlet, which is beneficial to the cooling of the components, such as the main motor and the first radiator, etc. In addition, by arranging the air outlet on the upper side of the air inlet, it is also beneficial to reducing the reflection and transmission of noise among the devices in the noise reduction cabin, thus being beneficial to reducing the noise. For example, as shown inFIGS.1-3, the noise reduction cabin400includes a cabin top wall430. The cabin top wall430refers to a cabin wall farthest from the platform500in the noise reduction cabin400. For example, the cabin top wall430is closer to the first radiator300than the platform500. By arranging the first radiator closer to the cabin top wall, it can be beneficial for the first radiator to blow upward to dissipate heat, and it can achieve better noise reduction effect while dissipating heat form the lubricating oil. For example, as shown inFIGS.1-3, the lubricating motor150can be located at a side of the main motor200away from the plunger pump110. For example, the lubricating motor150can be located between the first radiator300and the platform500. For example, the orthographic projection of the lubricating motor150on the supporting surface of the platform500overlaps with the orthographic projection of the first radiator300on the supporting surface. For example, the first radiator300is located directly above the lubricating motor150. In the fracturing apparatus provided by the present disclosure, the first radiator is arranged closer to the cabin top wall, and other device (such as the lubricating motor) is arranged between the first radiator and the platform, which can improve the utilization rate of the space in the noise reduction cabin. For example, as shown inFIGS.1-3, the first radiator300can be arranged on the frame of the noise reduction cabin400. For example, the first radiator300can be arranged on the cabin body of the noise reduction cabin400, and the main motor200and the lubricating motor150are covered in the cabin body by the noise reduction cabin400. For example, as shown inFIGS.1-3, the first radiator300is located at a side of the main motor200away from the plunger pump110, a second radiator210is provided at a side of the main motor200away from the platform500, the second radiator210is configured to dissipate heat from the main motor200, and the cabin top wall430is closer to the second radiator210than the platform500. For example, the second radiator210can be a cooling fan. For example, as shown inFIGS.1-3, both the first radiator300and the second radiator210are located close to the cabin top wall430, which is favorable for dissipating heat from the lubricating oil and the main motor. For example, a straight line parallel to the supporting surface of the platform500can pass through the first radiator300and the second radiator210. For example, the orthographic projections of the first radiator300and the second radiator210on a straight line perpendicular to the supporting surface overlap with each other. The embodiment of the present disclosure illustratively takes the second radiator as a component separated from the main motor, but it is not limited to this case, and the second radiator can also be integrated with the main motor. For example, as shown inFIGS.1-3, the cabin top wall430is provided with an air outlet420, the first radiator300includes a heat dissipation pipe310and a fan320, the heat dissipation pipe310is located between the fan320and the air outlet420, the fan320is configured to blow air to the heat dissipation pipe310to dissipate heat from the lubricating oil in the heat dissipation pipe310, and the heat dissipation pipe310is opposite to the air outlet420, so that the heat of the lubricating oil in the heat dissipation pipe310is directly discharged outside the cabin. For example, the heat dissipation pipe310is located above the fan320, that is, at a side of the fan320away from the platform500. For example, the air outlet420can have a mesh structure. For example, as shown inFIGS.1-3, the fan320is configured to blow and dissipate heat from the lubricating oil flowing in the heat dissipation pipe310, that is, the fan320blows the heat dissipation pipe310above it, so as to discharge the heat outside the cabin from the air outlet420. In the process that the fan320blows upward, negative pressure is formed inside the noise reduction cabin400, and the external air enters the noise reduction cabin400from the air inlet410, and flows to the air outlet420after passing through the devices in the noise reduction cabin400(such as the main motor200and the lubricating motor150, etc.), so as to cool the devices in the noise reduction cabin400and ensure the normal operation of the devices in the cabin. This process meets the air quantity required by the devices when working and the air quantity required for heat dissipation. In addition, the air outlet is arranged on the cabin top wall of the noise reduction cabin, so that the air outlet is located above the devices in the cabin, and the reflection and transmission of noise among the devices can be weakened. For example,FIG.4is a schematic view from one side corresponding to the fracturing apparatus shown inFIG.1. As shown inFIGS.1-4, the noise reduction cabin400includes a cabin side wall440and a cabin door450, and at least one of the cabin side wall440and the cabin door450is provided with an air inlet410. For example, the noise reduction cabin400can include four side surfaces and a top surface, the top surface is provided with a cabin top wall, one of the four side surfaces is provided with the cabin side wall440, the other three of the four side surfaces are provided with cabin doors450, and each side surface can be provided with two cabin doors450. Thus, the noise reduction cabin400can include one cabin top wall430, one cabin side wall440and six cabin doors450, and the cabin side wall440is located between the main motor200and the plunger pump110. For example, the cabin side wall440is provided with the air inlet410, and the three side surfaces where the cabin doors450are provided can all be provided with air inlets410. Therefore, the external air can enter the noise reduction cabin400from four different directions, which is more conducive to cooling the devices in the cabin. For example, as shown inFIGS.1-4, two cabin doors450on the same side can be provided with air inlets410, or one of the two cabin doors450on the same side can be provided with an air inlet410. FIG.4illustratively shows that the noise reduction cabin includes four side surfaces, but it is not limited to this case, and it may also include five or more side surfaces. For example, in the case where the noise reduction cabin includes four side surfaces, the number of side surfaces where the cabin side walls are arranged can be two, and the number of side surfaces where the cabin doors are arranged can be two; or, the number of side surfaces where the cabin side walls are arranged can be three, and the number of side surfaces where the cabin doors are arranged can be one, without being limited in the embodiment of the present disclosure. For example,FIG.4illustratively shows that each side surface includes two cabin doors, but it is not limited to this case, and it may also include one cabin door or more cabin doors. For example, the areas of the air inlets410on different cabin doors450and the area of the air inlet410on the cabin side wall440can be the same or different. For example, the air inlet410on the cabin side wall440can be directly opposite to the main motor200, and the external air entering from the air inlet410can cool the main motor200. A part of the air inlet410provided on the cabin door450which is close to both the main motor200and the lubricating motor150can be directly opposite to the main motor200, and the other part of the air inlet410can be directly opposite to the lubricating motor150, and the external air entering from the air inlet410can simultaneously cool the main motor200and the lubricating motor150. For example, as shown inFIGS.1-3, the fracturing apparatus further includes an electric control cabinet140, and the electric control cabinet140is located in the noise reduction cabin400, thereby not only reducing the noise generated by the electric control cabinet, but also reducing the risk that the electric control cabinet is damaged by high-pressure liquid in the plunger pump. For example, as shown inFIGS.1-3, the main motor200is located between the electric control cabinet140and the plunger pump110. For example, the main motor200can be electrically connected with electrical devices in the electric control cabinet140. For example, a frequency converter141is provided in the electric control cabinet140, and the main motor200can be electrically connected with the frequency converter131. For example, the lubricating motor150and other devices can also be connected with cables from the frequency converter141in the electric control cabinet140. For example, the electric control cabinet140is located between the first radiator300and the platform500, and the orthographic projection of the electric control cabinet140on the supporting surface of the platform500overlaps with the orthographic projection of the first radiator300on the supporting surface. For example, the electric control cabinet140and the lubricating motor150are both arranged on the platform500and both located between the first radiator300and the platform500, which can effectively utilize the space in the noise reduction cabin. For example, the external air entering from the air inlet410on the cabin door450adjacent to the electric control cabinet140can cool the electric control cabinet140. For example,FIG.5is a schematic view of a cabin door located at a side of a main motor away from a plunger pump in the noise reduction cabin shown inFIG.4. As shown inFIGS.1-5, two cabin doors450located at a side of the main motor200away from the plunger pump110, after being opened, can expose the electric control cabinet140, the lubricating motor150and the first radiator300. For example, the two doors450, after being opened, can further expose a filter, and the filter is configured to filter the lubricating oil in the oil pipe. For example, the filter can be connected in the pipeline of oil pipe for transporting lubricating oil, and the lubricating oil flowing through the filter can be filtered by the filter. For example, the filter can be located on the oil inlet pipeline of the plunger pump110or on the oil outlet pipeline of the plunger pump110. For example, as shown inFIGS.1-5, two cabin doors450located at a side of the main motor200away from the plunger pump110include a first cabin door451and a second cabin door452, the first cabin door451is configured to expose the electric control cabinet140upon being opened, and the second cabin door452is configured to expose the lubricating motor150upon being opened. For example, the second cabin door452can further expose the filter as mentioned above upon being opened. For example, a part of the first radiator300can be exposed after the first cabin door451is opened, and the other part of the first radiator300can be exposed after the second cabin door452is opened. For example, in the case where the two cabin doors450are closed, the second cabin door452overlaps with the first cabin door451. For example, the part of the first cabin door451close to the second cabin door452overlaps with the part of the second cabin door452close to the first cabin door451. For example, the overlapping part of the second cabin door452is located at the outer side of the overlapping part of the first cabin door451. For example, a part of the second cabin door452is pressed against the outer side of a part of the first cabin door451, so that the first cabin door451can be opened only after the second cabin door452is opened. For example, the maintenance frequency of the electric control cabinet140is lower than the maintenance frequency of the lubricating motor150. For example, the maintenance frequency of the electric control cabinet140is lower than the maintenance frequency of the filter. In order to facilitate the maintenance operations of the devices in the noise reduction cabin400, the electric control cabinet140can be placed behind the first cabin door451, and other devices with higher maintenance frequency, such as the lubricating motor150and the filter, etc., can be placed behind the second cabin door452, and the cabin door450is arranged in such a way that part of the second cabin door452is pressed against the outer side of part of the first cabin door451, so that only the second cabin door452needs to be opened to meet the small-scale maintenance of devices, such as the lubricating motor and the filter, etc. For example, the first cabin door451and/or the second cabin door452can further be provided with transparent windows or nested small doors. Through the transparent window, the components inside the noise reduction cabin can be observed; or by opening the nested small door, the components in the noise reduction cabin can be simply maintained without opening the first cabin door451and/or the second cabin door452. For example, one of the first cabin door451and the second cabin door452can further be provided with a touch screen, and the touch screen is connected with the electric control cabinet to control the working state of the devices in the noise reduction cabin400. Another embodiment of the present disclosure provides a fracturing apparatus, which includes a plunger pump, a transmission shaft, a main motor, a second radiator and a platform. The main motor is spaced apart from the plunger pump, and the plunger pump is connected with the main motor through the transmission shaft; the second radiator is configured to dissipate heat from the main motor; and the plunger pump and the main motor are both located on the platform. The fracturing apparatus further includes a noise reduction cabin located on the platform, the main motor and the second radiator are both located in the noise reduction cabin; the noise reduction cabin is provided with a noise reduction structure, the noise reduction structure is configured to reduce the noise of the second radiator; and a distance between an end or a plane of the noise reduction structure farthest from the platform and the platform is not less than the distance between the second radiator and the platform. In the fracturing apparatus provided by the embodiment of the present disclosure, the main motor and the second radiator used to dissipate heat from the main motor are arranged in the noise reduction cabin, and the noise reduction structure used to reduce the noise of the second radiator is arranged in the noise reduction cabin, which is beneficial to improving the noise reduction effect of the main motor and the second radiator in the fracturing apparatus. In addition, by setting the relative positional relationship between the noise reduction structure and the second radiator, the noise of the second radiator can be discharged to a side away from the platform, which is beneficial to reducing the reflection and transmission of the noise among the devices in the noise reduction cabin and further reducing the noise. FIG.6is a partial cross-sectional structural view of the noise reduction cabin of the fracturing apparatus shown inFIG.1. As shown inFIGS.1and6, the second radiator210is configured to dissipate heat from the main motor200. For example, the second radiator210is located at the top of the main motor200, the fan blades included in the second radiator210operate (suction type), and the external air enters the noise reduction cabin through the shutters of the noise reduction cabin (described later), then passes through the air inlet at the bottom of the main motor200, takes away a part of the heat through the main motor cavity (stator and rotor), and then is discharged to the air outlet of the cabin body through the volute and the fan blades, thus realizing the heat dissipation of the main motor200. For example, as shown inFIGS.1and6, the second radiator210is located at a side of the main motor200away from the platform500. The embodiment of the present disclosure illustratively shows that the second radiator and the main motor are two components separated from each other, but it is not limited to this case, and the second radiator and the main motor can also have an integrated structure, and they can be integrated as a whole. As shown inFIGS.1and6, both the main motor200and the second radiator210are located in the noise reduction cabin400, the noise reduction cabin400is provided with a noise reduction structure4100, the noise reduction structure4100is configured to reduce the noise of the second radiator210, and at least part of the noise reduction structure4100is located at a side of the second radiator210away from the platform500. In the fracturing apparatus, the second radiator configured to dissipate heat from the main motor is the key component to generate noise. In the fracturing apparatus provided by the present disclosure, the main motor and the second radiator for dissipating heat from the main motor are arranged in the noise reduction cabin, and the noise reduction structure for reducing noise of the second radiator is arranged in the noise reduction cabin, which is beneficial to improving the noise reduction effect of the main motor and the second radiator of the fracturing apparatus. For example, as shown inFIGS.1and6, the direction indicated by the arrow in the Y direction is upward, and at least part of the noise reduction structure4100is obliquely above the second radiator210. For example, at least part of the noise reduction structure4100is obliquely above the fan of the second radiator210. In the fracturing apparatus provided by the present disclosure, by setting the relative positional relationship among the noise reduction structure, the second radiator and the platform, the noise of the second radiator can be discharged to a side away from the platform, which is beneficial to reducing the reflection and transmission of the noise among the devices in the noise reduction cabin and reducing the noise. For example, as shown inFIGS.1and6, the cabin top wall430can be parallel to the supporting surface of the platform500, but it is not limited thereto. In the present disclosure, “parallel to” means that the angle therebetween is not greater than 10 degrees. For example, as shown inFIGS.1and6, the cabin top wall430is closer to the second radiator210than the platform500. For example, the distance between the fan of the second radiator210and the cabin top wall430can be less than the distance between the fan and the platform500. By arranging the second radiator closer to the cabin top wall, it can be beneficial for the second radiator to discharge noise upwards, so as to achieve better noise reduction effect. For example, as shown inFIGS.1and6, the noise reduction cabin400further includes a cabin side wall440, and the cabin side wall is a cabin wall intersected with the supporting surface of the platform500in the noise reduction cabin, for example, the cabin side wall440can contact with the platform500and be fixed on the platform500. For example, the noise reduction structure4100is disposed on at least one of the cabin top wall430and the cabin side wall440. For example,FIG.1illustratively shows that the noise reduction structure is arranged on the cabin side wall, which is beneficial to saving the space of the fracturing apparatus, but it is not limited to this case, and the noise reduction structure can also be arranged on the cabin top wall of the noise reduction cabin. For example, as shown inFIGS.1and6, the noise reduction structure4100includes a labyrinth noise reduction portion4110. For example, as shown inFIGS.1and6, the labyrinth noise reduction portion4110can include a plurality of baffle plates4111; for example, each baffle plate4111can include a plurality of sub-portions041to form a bending portion, and the plurality of baffle plates4111form a labyrinth structure, so that the noise will be blocked by the baffle plates and refracted when it propagates, thus achieving the purpose of noise reduction. For example, the labyrinth noise reduction portion4110can include a bent steel plate and sound-absorbing cotton adhered to the steel plate. For example, as shown inFIGS.1and6, the labyrinth noise reduction portion4110includes a plurality of baffle plates4111arranged in a direction perpendicular to the supporting surface of the platform500, and a gap is provided between adjacent baffle plates4111for discharging noise. For example, each baffle plate4111includes at least two sub-portions041connected in sequence.FIG.6illustratively shows that each baffle plate4111includes two sub-portions041connected in sequence, but it is not limited thereto, and each baffle plate4111can also include three or more sub-portions. For example, as shown inFIGS.1-6, the sub-portions041included in each baffle plate4111can have an integrally formed structure. Of course, the embodiment of the present disclosure is not limited thereto, and the plurality of sub-portions included in at least one bending portion may not have an integrally formed structure. For example, as shown inFIGS.1and6, each baffle plate4111includes two sub-portions041connected in sequence, each baffle plate4111includes a first sub-portion close to the second radiator210and a second sub-portion away from the second radiator210, a distance between an end of the first sub-portion close to the second radiator210and the platform500is less than a distance between an end of the first sub-portion away from the second radiator210and the platform500, and a distance between an end of the second sub-portion close to the second radiator210and the platform500is greater than a distance between an end of the second sub-portion away from the second radiator210and the platform500. For example, the first sub-portion and the second sub-portion form an inverted V-shape, and the shape of the gap between adjacent baffle plates4111also forms an inverted V-shape; the second radiator210is located obliquely below at least part of the gaps, and the noise generated by the second radiator210enters the inverted V-shape gap during upward propagation, and then is discharged to the outer side of the noise reduction cabin through these gaps. FIG.6illustratively shows that the shape of the baffle plate included in the labyrinth noise reduction portion is a bent shape, but it is not limited thereto, and the baffle plate can also be in a plate shape of a cuboid. For example, as shown inFIGS.1and6, the noise reduction structure4100further includes a noise reduction channel042between the labyrinth noise reduction portion4110and the second radiator210, and the noise reduction channel042connects the labyrinth noise reduction portion4110with the second radiator210. For example, the labyrinth noise reduction portion4110is located obliquely above the fan of the second radiator210. In this case, the noise reduction channel042extends obliquely upward from the second radiator210to be connected to the labyrinth noise reduction portion4110, and the noise generated by the fan of the second radiator210propagates to the labyrinth noise reduction portion4110through the noise reduction channel042. For example, the noise reduction channel042can include a first channel0421close to the second radiator210and a second channel0422away from the second radiator210. For example, the second channel0422is connected with the labyrinth noise reduction portion4110. For example, the second channel0422can be made of the same material as and integrally formed with the labyrinth noise reduction portion4110. For example, the first channel0421can be made of a flexible material, such as a hose, so as to connect the second channel0422with the second radiator210. For example, the first channel0421can send hot air to the second channel0422. For example, the motor in the second radiator210will inevitably vibrate during operation, and the first channel0421adopts a flexible material to realize the soft connection between the second channel0422and the second radiator210, which is beneficial to absorbing the vibration and improving the stability. For example, the noise reduction channel042can also be provided with a component for noise reduction, such as a sound-absorbing material, etc. Of course, the embodiment of the present disclosure is not limited to that the noise generated by the fan of the second radiator propagates to the noise reduction structure, and the noise generated by the driving motor of the second radiator can also propagate to the noise reduction structure, and the noise reduction structure is configured to reduce the noise of the whole second radiator. For example, as shown inFIGS.1and6, the noise reduction structure4100can be arranged on the cabin side wall440. For example, the noise reduction structure4100is located at the top of the cabin side wall440and contacts with the cabin top wall430. However, it is not limited to this case. The noise reduction structure4100can also be located on the middle and upper part of the cabin side wall440, that is, the cabin side wall440is arranged above and below the noise reduction structure4100. For example, the noise reduction structure4100can be fixed on the cabin side wall440. For example, as shown inFIGS.1and6, the noise reduction structure4100further includes a noise reduction cavity4120, and for example, the noise reduction cavity4120can be an empty cavity. For example, a labyrinth noise reduction portion4110is arranged at the opening4121of the noise reduction cavity4120facing the main motor200. For example, the labyrinth noise reduction portion4110is located between the noise reduction cavity4120and the second radiator210, and the noise discharged from the labyrinth noise reduction portion4110will enter the noise reduction cavity4120. For example, as shown inFIGS.1and6, the noise reduction cavity4120protrudes to a side away from the main motor220with respect to the cabin side wall440to form an empty cavity. For example, as shown inFIGS.1and6, the plunger pump110is located at the outer side of the noise reduction cabin400, and the noise reduction structure4100is located between the main motor200and the plunger pump110. For example, the noise reduction cavity4120protrudes outward relative to the cabin side wall440of the noise reduction cabin400facing the plunger pump110, which is beneficial to saving the space of the fracturing apparatus. For example, as shown inFIGS.1and6, the orthographic projection of the noise reduction cavity4120on the platform500overlaps with the orthographic projection of the transmission shaft120on the platform500. For example, the orthographic projection of the noise reduction cavity4120on the platform500does not overlap with the orthographic projection of the plunger pump110on the platform500. For example, as shown inFIGS.1-6, along the direction perpendicular to the XY plane, the width of the noise reduction cavity4120can be equal to the width of the cabin side wall440of the noise reduction cabin400, so as to maximize the volume of the noise reduction cavity4120and further improve the noise reduction effect. The present disclosure is not limited to this case, and the width of the noise reduction cavity can also be less than the width of the cabin side wall of the noise reduction cabin, and the width of the noise reduction cavity can be set according to actual product requirements. For example, as shown inFIGS.1and6, the noise reduction cavity4120is located at a side of the main motor200away from the platform500, so that the noise reduction cavity can discharge noise to a side away from the platform. For example, the orthographic projection of the noise reduction cavity4120on a straight line perpendicular to the supporting surface of the platform500does not overlap with the orthographic projection of the main motor200on the straight line. For example, the orthographic projection of the noise reduction cavity4120on the straight line perpendicular to the supporting surface of the platform500can overlap with the orthographic projection of the second radiator210on the straight line. For example, as shown inFIGS.1and6, an exhaust outlet460is provided at a side of the noise reduction cavity4120away from the main motor200, and the exhaust outlet460is configured to exhaust the noise in the noise reduction cavity4120outside the noise reduction cabin. For example, as shown inFIGS.1and6, the exhaust outlet460is located at the upper part of the noise reduction cavity4120, so that the noise discharged into the noise reduction cavity4120by the second radiator210through the labyrinth noise reduction portion4110can be discharged from the upper part of the noise reduction cavity4120. For example, the noise discharged into the noise reduction cavity4120through the labyrinth noise reduction portion4110can be reflected at least once in the noise reduction cavity4120and then discharged from the exhaust outlet460, and the noise being reflected at least once by the noise reduction cavity can improve the noise reduction effect. For example, as shown inFIGS.1and6, a distance between an end of the exhaust outlet460close to the labyrinth noise reduction portion4110and the supporting surface of the platform500is greater than a distance between an end of the exhaust outlet460away from the labyrinth noise reduction portion4110and the supporting surface, so that the exhaust outlet460exhausts air obliquely upward away from the platform500. For example, the exhaust outlet460can be provided with silencing shutters, which can not only achieve better circulation and exhaust air, but also have a noise reduction effect. For example, as shown inFIGS.1and6, a first sound-absorbing layer0420is provided at the inner wall of the noise reduction cavity4120, and the first sound-absorbing layer0420is configured to further reduce the noise exited from the labyrinth noise reduction portion4110. For example, the first sound-absorbing layer0420can include a sound-absorbing material and a porous plate, the sound-absorbing material can include glass wool, the noise is reflected between the porous plate and the glass wool for multiple times, and after the aperture and pitch of the porous plate are determined, resonance attenuation can occur to achieve the noise reduction effect. For example, the labyrinth noise reduction portion4110and the noise reduction cavity4120can work together to make the noise value at the outer side of the cabin meet the requirements. For example, after the noise reduction structure set in the noise reduction cabin reduces the noise of the devices, such as the second radiator, etc., the fracturing apparatus can meet the requirements of SY/T 7086 fracturing pumping apparatus. For example,FIG.7is a partial cross-sectional structural view of a labyrinth noise reduction portion according to another example in the embodiment of the present disclosure. The labyrinth noise reduction portion4110′ shown inFIG.7can replace at least one of the labyrinth noise reduction portion4110and the noise reduction cavity4120shown inFIG.6. Combining the components, other than the labyrinth noise reduction portion4110and the noise reduction cavity4120inFIG.6, with the labyrinth noise reduction portion4110′ shown inFIG.7, the labyrinth noise reduction portion4110′ includes a plurality of baffle plates4111′ arranged in the direction perpendicular to the supporting surface of the platform, each baffle plate4111′ includes at least two sub-portions041′ connected in sequence to form a bending portion, and a gap is arranged between adjacent baffle plates4111′. In each baffle plate4111′, the sub-portion041′ farthest from the second radiator210extends in a direction away from the platform500, so as to discharge noise from the cabin obliquely upward away from the platform500. For example,FIG.7illustratively shows that each baffle plate4111′ includes three sub-portions041′ connected in sequence, but it is not limited to this case, and the number of sub-portions in each baffle plate can be two or more. For example, the labyrinth noise reduction portion4110′ shown inFIG.7can replace only the labyrinth noise reduction portion shown inFIG.6, and for example, the labyrinth noise reduction portion4110′ shown inFIG.7can be combined with the noise reduction cavity4120shown inFIG.6to achieve the noise reduction effect together. For example,FIG.3is a schematic view from one side corresponding to the noise reduction cabin shown inFIG.6, andFIG.8is a schematic view from the other side corresponding to the noise reduction cabin shown inFIG.6. As shown inFIGS.3and8, a second sound-absorbing layer043is provided at a side, facing the interior of the noise reduction cabin400, of at least one of the cabin top wall430, the cabin side wall440and the cabin door450. For example, in addition to the main motor200and the second radiator210, devices, such as an oil radiator, a lubricating motor, an electric control cabinet, etc., are also provided in the noise reduction cabin. The noise generated by various devices in the noise reduction cabin400propagates around in the interior of the noise reduction cabin400and is absorbed by the second sound-absorbing layer043arranged in the cabin, thus achieving a better noise reduction effect. For example, the second sound-absorbing layer043can include a sound-absorbing material and a porous plate, the sound-absorbing material can include glass wool, the noise is reflected between the porous plate and the glass wool for multiple times, and after the aperture and pitch of the porous plate are determined, resonance attenuation can occur to achieve the noise reduction effect. For example, as shown inFIG.3, the exhaust outlet460is provided with a cover plate471. After the fracturing apparatus is turned off, the cover plate471can be covered on the exhaust outlet460to prevent external rain or snow from floating into the noise reduction cavity4120through the exhaust outlet460in rainy or snowy weather or to prevent other impurities from falling into the noise reduction cavity4120through the exhaust outlet. For example,FIG.9is an enlarged view of a supporting plate and an exhaust outlet in the noise reduction cabin shown inFIG.8, andFIG.10is a side view of the exhaust outlet shown inFIG.9. As shown inFIGS.3and8-10, a flow guide groove472is provided at a side of the noise reduction cavity4120close to the platform500. When liquid, such as rain, enters the cavity through the exhaust outlet460provided in the noise reduction cavity4120, the liquid can be discharged from the noise reduction cavity4120through the flow guide groove472. For example, as shown inFIGS.3and8-10, at least one drain hole4610can be provided at the bottom of the noise reduction cavity4120close to the platform50, and the drain hole4610can be communicated with the flow guide groove472. When liquid enters the noise reduction cavity4120, the liquid flows into the flow guide groove472through the drain hole4610and flows out from the flow guide groove472. For example, as shown inFIGS.3and8-10, the drain hole4610and the flow guide groove472can both be arranged at a side of the noise reduction cavity4120away from the second radiator210. For example, as shown inFIGS.3and8-10, the drain holes4610can be uniformly distributed at the bottom of the noise reduction cavity4120, the flow guide groove472includes a flow guide pipe4620communicated with the drain holes4610, the flow guide pipe4620discharge the liquid into the flow guide groove472, and then the flow guide groove472discharges the liquid. For example, the above-mentioned flow guide pipe4620includes an inclined plane, a distance between a side of the inclined plane close to the second radiator210and the platform500is greater than a distance between a side of the inclined plane away from the second radiator210and the platform500. The inclined plane can be used as a pipeline for transporting liquid and transport liquid to one side farthest from the second radiator210, at least one drain hole4610is also arranged at a side of the inclined plane farthest from the second radiator210, and the flow guide groove472is arranged at one side of the flow guide pipe4620farthest from the second radiator210and is communicated with the drain hole4610. For example, as shown inFIGS.1-4, a hook473is provided at a surface of the noise reduction cavity4120away from the main motor200, and the hook473overlaps with the transmission shaft120in the direction perpendicular to the supporting surface of the platform500. For example, the hook473can be an auxiliary hook for hoisting the transmission shaft. In the embodiment of the present disclosure, by arranging the auxiliary hook for hoisting the transmission shaft at the outer side of the noise reduction cabin, for example, at the outer side of the noise reduction cavity, the transmission shaft can be hoisted and stopped at the installation position with the help of the hook arranged on the noise reduction cabin when the transmission shaft is disassembled and assembled, so that the installation difficulty is reduced. For example, as shown inFIGS.3and8-9, a plurality of supporting plates arranged along the extending direction of the noise reduction cavity4120are provided at one side of the noise reduction cavity4120away from the labyrinth noise reduction portion4110. A gap is provided between adjacent supporting plates461, and a plurality of gaps formed by the plurality of supporting plates461form an exhaust outlet460. For example, a noise reduction component (e.g., the first sound-absorbing layer0420), such as a sound-absorbing material and a porous plate, etc., can be provided on the surface of at least one supporting plate461to further reduce noise. For example, a first sound-absorbing layer0420can be provided on the surface of each supporting plate461. In the embodiment of the present disclosure, by arranging a plurality of supporting plates at a side of the noise reduction cavity away from the second radiator, a noise reduction type exhaust outlet can be formed, and at the same time, the load-bearing capacity of the noise reduction cavity can be improved, so that the load-bearing capacity of the auxiliary hook for hoisting the transmission shaft can be improved, and the disassembly and assembly of the transmission shaft can be facilitated. The following statements should be noted:(1) In the accompanying drawings of the embodiments of the present disclosure, the drawings involve only the structure(s) in connection with the embodiment(s) of the present disclosure, and other structure(s) can be referred to common design(s).(2) In case of no conflict, features in one embodiment or in different embodiments can be combined. What have been described above are only specific implementations of the present disclosure, the protection scope of the present disclosure is not limited thereto, and the protection scope of the present disclosure should be based on the protection scope of the claims | 51,097 |
11859482 | DETAILED DESCRIPTION Some implementations of the present disclosure will now be described more fully hereinafter with reference to the accompanying figures, in which some, but not all implementations of the disclosure are shown. Indeed, various implementations of the disclosure may be embodied in many different forms and should not be construed as limited to the implementations set forth herein; rather, these example implementations are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Like reference numerals refer to like elements throughout. Unless specified otherwise or clear from context, references to first, second or the like should not be construed to imply a particular order. A feature may be described as being above another feature (unless specified otherwise or clear from context) may instead be below, and vice versa; and similarly, features described as being to the left of another feature else may instead be to the right, and vice versa. Also, while reference may be made herein to quantitative measures, values, geometric relationships or the like, unless otherwise stated, any one or more if not all of these may be absolute or approximate to account for acceptable variations that may occur, such as those due to engineering tolerances or the like. As used herein, unless specified otherwise or clear from context, the “or” of a set of operands is the “inclusive or” and thereby true if and only if one or more of the operands is true, as opposed to the “exclusive or” which is false when all of the operands are true. Thus, for example, “[A] or [B]” is true if [A] is true, or if [B] is true, or if both [A] and [B] are true. Further, the articles “a” and “an” mean “one or more,” unless specified otherwise or clear from context to be directed to a singular form. FIG.1illustrates a system100for fracturing a well according to some example implementations of the present disclosure. As shown, the system generally includes a plurality of plurality of hydraulic fracturing units102configured to pump a fracturing fluid, and a manifold104from which the fracturing fluid is delivered to the well. More particularly, in the system100shown inFIG.1, water from tanks106and gelling agents dispensed by a chemical unit108are mixed in a hydration unit110. The discharge from hydration unit, along with sand carried on conveyors112from sand tanks114is fed into a blender116that mixes the gelled water and sand into fracturing fluid (a slurry). The blender discharges the fracturing fluid through low-pressure hoses that convey it into two or more low-pressure lines in the manifold104. The low-pressure lines in the manifold feed the fracturing fluid to the hydraulic fracturing units102, perhaps as many as a dozen or more, through low-pressure “suction” hoses. The hydraulic fracturing units102take the fracturing fluid and discharge it at high pressure through individual high-pressure “discharge” lines into two or more high-pressure lines or “missiles” on the manifold104. The missiles flow together, i.e., they are manifolded on the manifold. Several high-pressure flow lines run from the manifolded missiles to a “goat head” that delivers the fracturing fluid into a “zipper” manifold. The zipper manifold allows the fracturing fluid to be selectively diverted to, for example, one of two well heads. Once fracturing is complete, flow back from the fracturing operation discharges into a flowback manifold which leads into flowback tanks. Because systems for fracturing a well are required on site for a relatively short period of time, the larger components of the system100typically are transported to a well site on skids, trailers, or trucks as more or less self-contained units. They then are connected to the system by one kind of conduit or another. InFIG.1, for example, the hydraulic fracturing units, chemical unit108, hydration unit110and blender116may be mounted on a trailer that is transported to the well site by a truck. Because they are designed to be more or less self-contained units, however, they are complex machines and incorporate several distinct subsystems and a large number of individual components. FIG.2illustrates a hydraulic fracturing unit102according to some example implementations of the present disclosure. The hydraulic fracturing unit includes a chassis204, and a pump206, such as a reciprocating pump, connected to the chassis and configured to pump a fracturing fluid. In some examples, the chassis may include a trailer (e.g., a flat-bed trailer) and/or a truck body to which the components of the hydraulic fracturing unit may be connected. For example, the components may be carried by trailers and/or incorporated into trucks, so that they may be easily transported between well sites. The pump206may be reciprocating plunger pump including a power end and a fluid end. The power end transforms rotational motion and energy from a powertrain208into the reciprocating motion that drives plungers in the fluid end. In the fluid end, the plungers force fluid into a pressure chamber that is used to create high pressure for well servicing. The fluid end may also include a discharge valve assembly and a suction valve assembly. The hydraulic fracturing unit102includes the powertrain208also connected to the chassis and configured to power the pump. In this regard, the powertrain includes a prime mover210and a drivetrain212. In some examples, the hydraulic fracturing unit is a direct drive turbine (DDT) unit in which the prime mover is or includes a gas turbine engine (GTE)214. As also shown, the drivetrain includes a reduction transmission216(e.g., gearbox) connected to a drive shaft218, which, in turn, is connected to the pump such as via an input shaft or input flange of the pump. Other types of GTE-to-pump arrangements are contemplated. In some examples, the GTE214may be a direct drive GTE. The GTE may be a dual-fuel or bi-fuel GTE, for example, operable using of two or more different types of fuel, such as natural gas and diesel fuel, although other types of fuel are contemplated. For example, a dual-fuel or bi-fuel GTE may be capable of being operated using a first type of fuel, a second type of fuel, and/or a combination of the first type of fuel and the second type of fuel. For example, the fuel may include compressed natural gas (CNG), natural gas, field gas, pipeline gas, methane, propane, butane, and/or liquid fuels, such as, for example, diesel fuel (e.g., #2 Diesel), bio-diesel fuel, bio-fuel, alcohol, gasoline, gasohol, aviation fuel, etc. Gaseous fuels may be supplied by CNG bulk vessels, a gas compressor, a liquid natural gas vaporizer, line gas, and/or well-gas produced natural gas. Other types and sources of fuel are contemplated. The GTE may be operated to provide horsepower to drive the pump206via the drivetrain212to safely and successfully fracture a formation during a well stimulation project. As also shown, the hydraulic fracturing unit102includes auxiliary equipment220located onboard the chassis204, and configured to support operation of the hydraulic fracturing unit including the pump206and the powertrain208. As described above, the auxiliary equipment onboard the hydraulic fracturing unit may include lubrication and cooling equipment such as cooling fans and lubrication pumps. More particular examples of auxiliary equipment include a lube oil pump coupled to the reduction transmission216, a cooling fan coupled to a reduction transmission lube oil pump, a lube oil pump coupled to the power end of the pump, a cooling fan coupled to a power end lube oil pump, a cooling fan to the GTE214, a GTE air cooling fan, a screw type air compressor, an air dryer, greater equipment for the pump206, an air intake blower fan motor, a GTE controller, a hydraulic starter pump, a GTE lube cooling fan, a telescope exhaust winch, a master programmable logic controller (PLC), and the like. As shown inFIG.3, example implementations of the present disclosure provide a power arrangement300configured to power the auxiliary equipment220. As explained in greater detail below, the system100may include the power arrangement may be located onboard the hydraulic fracturing unit102, such as on the gooseneck of a trailer. Additionally or alternatively, the system100may include the power arrangement configured to power the auxiliary equipment across the plurality of hydraulic fracturing units if not also backside equipment such as the chemical unit108, hydration unit110, conveyors112, sand tanks114, blender116and the like. In some examples, the backside equipment may also include a data center118. As shown, the power arrangement300generally includes a power source302and a power network304. The power source is configured to generate power for the auxiliary equipment. The power network is coupled to the power source and the auxiliary equipment, and configured to deliver the power generated by the power source to the auxiliary equipment. In various examples, the power arrangement300may be an electric power arrangement or a hydraulic power arrangement.FIG.4illustrates an example in which the power arrangement300is an electric power arrangement400. In this example, the power source224is an electric power source402configured to generate electric power for the auxiliary equipment220, and the power network is an electric power network404configured to deliver the electric power to the auxiliary equipment, which may include one or more electric motors406. As shown inFIG.4, in some examples, the electric power source402includes an engine-generator set408with an engine410, such as a reciprocating engine or GTE412, and an electric generator such as an electric motor generator414. One example of a suitable reciprocating engine is a diesel engine such as a tier four diesel engine, and one example of a suitable electric motor generator is a permanent magnet (PM) motor generator. One particular example of a suitable GTE412that could be made part of the electric power source402is a microturbine from Capstone Turbine Corporation, although other turbines with similar technology and compact foot print could also be used. Gas turbine engines such as Capstone microturbines can be installed individually or in a parallel multipack configuration to create a local power grid that can be quiet, lightweight, modular and have low maintenance. Capstone microturbines and others like them have similar fuel capabilities to that of the Vericor TF50F turbine engine in such a way that even though natural gas is their preferred fuel source, diesel can be introduced as fuel for the turbine for a short period of time making this turbine adaptable to operating conditions and fuel shortage scenarios. The utilization of a microturbine as the GTE412in the electric power source402may result in lower emissions to that of a reciprocating engine such as a diesel engine. This may allow for a single fuel hook up for CNG, reduce total operating costs, and reduce the power generation package size on the hydraulic fracturing unit102. Other machinery and components associated with the main turbine air intake conditioning such as chillers and filters may also be shared with this microturbine. In some examples, the electric power arrangement400further includes a connection416to shore power from an external source of electric power, such as a utility power grid, another engine-generator set or the like, from which the auxiliary equipment220are also powerable. Additionally or alternatively, in some examples, the electric power arrangement further includes a battery bank418chargeable from the power generated by the electric motor generator414, and from which the auxiliary equipment are also powerable. The battery bank may include one or more batteries such as lithium on or lead acid batteries. In some examples in which the power arrangement300is onboard the hydraulic fracturing unit102, and the hydraulic fracturing units of the system100include respective power arrangements, the electric power arrangement further includes a connection420to a second power arrangement of a neighboring hydraulic fracturing unit from which the auxiliary equipment are also powerable. The auxiliary equipment220may be powered from the engine-generator set408, the shore power from the external source of electric power, the second electric power arrangement from a neighboring hydraulic fracturing unit102, or the battery bank418. In some examples, the electric power network404is configured to deliver the electric power generated by the engine-generator set to the electric motors406to drive the auxiliary equipment. In some of these examples in which the engine-generator set experiences a fault or failure, the electric power network may then, in response, switchably connect the utility power grid, the battery bank or the second engine-generator set to deliver power to the electric motors. FIG.5illustrates an example in which the power arrangement300is a hydraulic power arrangement500. In this example, the power source224is a hydraulic power source502configured to generate hydraulic power for the auxiliary equipment220, and the power network is a hydraulic power network504configured to deliver the hydraulic power to the auxiliary equipment, which may include one or more hydraulic motors506. As shown inFIG.5, the hydraulic power source502includes a second prime mover508, such as a reciprocating engine or an electric motor510, connected to a plurality of pumps512via a hydraulic pump drive514. One example of a suitable electric motor is a PM motor. In some examples, the hydraulic power arrangement further includes a connection516to shore power from an external source of electric power, such as a utility power grid, another engine-generator set or the like, from which the electric motor may be powered. FIG.6illustrates another example in which the power arrangement300is a hydraulic power arrangement600. Similar toFIG.5, in this example, the power source224is a hydraulic power source602configured to generate hydraulic power for the auxiliary equipment220, and the power network is a hydraulic power network504configured to deliver the hydraulic power to the auxiliary equipment, which may include hydraulic motors606. As shown inFIG.6, however, the hydraulic power source includes a plurality of power takeoffs (PTOs)608connected to the transmission216of the hydraulic fracturing unit102. Each of the plurality of PTOs is equipped with a second prime mover610, such as an electric motor generator612, and a pump614. The hydraulic power source therefore including a plurality of PTOs with respective second prime movers and pumps. As indicated above, the power arrangement300the power arrangement may be located onboard the hydraulic fracturing unit102.FIG.7illustrates an example implementation of a hydraulic fracturing unit702in which the power arrangement300is connected to the chassis and configured to power the auxiliary equipment220.FIGS.8,9and10illustrate examples of a system800including a plurality of these hydraulic fracturing units702with respective power arrangements. As shown inFIGS.7and8, the system800for fracturing a well includes a plurality of hydraulic fracturing units702including respective pumps206configured to pump a fracturing fluid. The plurality of hydraulic fracturing units include respective powertrains208configured to power the respective pumps, and respective auxiliary equipment220configured to support operation of respective ones of the plurality of hydraulic fracturing units including the respective pumps and the respective powertrains. In addition, the plurality of hydraulic fracturing units further includes respective power arrangements300configured to power to the respective auxiliary equipment. In some examples, the plurality of hydraulic fracturing units702include neighboring hydraulic fracturing units, and the respective power arrangements300of the neighboring hydraulic fracturing units are connected to one another, and from which the respective auxiliary equipment220of the neighboring hydraulic fracturing units are also powerable. This is shown by power cables802between neighboring hydraulic fracturing units inFIG.8. In the event power is lost on a hydraulic fracturing unit702equipped with a respective power arrangement300, an automatic switching mechanism may allow neighboring hydraulic fracturing units joined by a receptacle and plug to share power. The neighboring hydraulic fracturing unit, then, may be able to provide power to the hydraulic fracturing unit allowing its auxiliary equipment. If for some reason both hydraulic fracturing units wanted to operate at the same time and distribute both of their power to a third hydraulic fracturing unit, the inclusion of synchronizing components such as a synchro scope may ensure the speed and frequency of their power arrangements are the same. As shown inFIGS.9and10, in some examples, the system800further includes a battery bank904connected to the respective power arrangements of the hydraulic fracturing units702that are configured to generate power from which the battery bank is chargeable. In some of these examples, the battery bank is configured to power the respective auxiliary equipment220from the power generated by the respective power arrangements. In addition, backside equipment such as one or more of the chemical unit108, hydration unit110, conveyors112, sand tanks114, blender116or data center118may be powered by the battery bank. InFIG.9, the battery bank904is directly connected to the respective power arrangements by respective power cables906. InFIG.10, in some examples, the system800further includes an electric bus1008connecting the respective power arrangements of the hydraulic fracturing units702, if not also the backside equipment, to the battery bank. The electric bus may also function as the power share and distribution path. In some of these other examples, the electric bus is connected to the manifold104. Even further, in some examples, the battery bank is also connected to shore power from an external source of electric power (e.g., utility power grid), from which the battery bank may also be chargeable and/or the respective auxiliary equipment may also be powerable. This is shown inFIGS.9and10in which the battery bank is connected to the data center118that is in turn connected to shore power from the external source of electric power. In other example implementations, the system may include the power arrangement configured to power the auxiliary equipment across the plurality of hydraulic fracturing units102if not also backside equipment such as the chemical unit108, hydration unit110, conveyors112, sand tanks114, blender116, data center118and the like.FIGS.11,12,13and14illustrate examples of a system1100including a plurality of hydraulic fracturing units, and a power arrangement300connected to the hydraulic fracturing units, and configured to power the respective auxiliary equipment220across hydraulic fracturing units. In addition, backside equipment may be powered by power arrangement. Due to high amperage draw from hydraulic fracturing units102, single power cables carrying the necessary voltage from the power arrangement300to the hydraulic fracturing units may not be suitable due to this amperage rating being unachievable. Each hydraulic fracturing unit that relies on the power arrangement to power its auxiliary equipment may have a divided bus to allow the total amperage to the hydraulic fracturing unit to be halved over an aluminum or copper bus bar allowing a single power cable to power each bus. Some backside equipment such as the chemical unit108and data center118may not require high continuous power and can be equipped with a single power distribution such as a bus bar. InFIG.11, the power arrangement300is directly connected to the hydraulic fracturing units102(and perhaps also the backside equipment) by respective power cables1102. InFIG.12, in some examples, the system1100further includes an electric bus1204connecting the hydraulic fracturing units (and perhaps also the backside equipment) to the power arrangement. Similar to before, in some of these other examples, the electric bus is connected to the manifold104. Even further, in some examples, the power arrangement is also connected to shore power from an external source of electric power (e.g., utility power grid), from which the respective auxiliary equipment may also be powerable. This is shown inFIGS.11and12in which the power arrangement is connected to the data center118that is in turn connected to shore power from the external source of electric power. As shown inFIGS.13and14, in some examples in which the power arrangement300is an electric power arrangement400, and includes is an electric power source402, the system further includes a battery bank1306chargeable from the power generated by the electric power arrangement. The battery bank may supply power to the equipment as required. Prior to commencing operations, if the battery bank is charged and fuel to the power arrangement300, the battery bank may act as a buffer to complete a job. In some examples, when the battery bank is charged, the power arrangement300may bypass the battery bank, and the battery bank may act as a hub to supply power to the hydraulic fracturing units102(and perhaps also the backside equipment). FIG.13is similar toFIG.11in that the battery bank1306is directly connected to the hydraulic fracturing units102(and perhaps also the backside equipment) by respective power cables1102.FIG.14is similar toFIG.12in that the system1100further includes the electric bus1204connecting the hydraulic fracturing units (and perhaps also the backside equipment) to the battery bank. InFIGS.13and14, the battery bank is configured to power the respective auxiliary equipment220across the plurality of hydraulic fracturing units102. Even further, in some examples, the battery bank is also connected to shore power from the external source of electric power (e.g., utility power grid via connection to the data center118), from which the battery bank may also be chargeable and/or the respective auxiliary equipment may also be powerable. To further illustrate example implementations of the present disclosure,FIG.15is a block diagram a particular electric power arrangement1500that in some examples may correspond to electric power arrangement400shown inFIG.4. As shown, the electric power arrangement may include a diesel engine1512and an electric generator1514to supply power to the system. In some examples, the diesel engine is a 225-300 HP Caterpillar C7 (maximum power rating of 300 HP and a speed between 1,800 to 2,200 RPM), a 335-456 BHP Caterpillar C9 (maximum power rating of 456 HP and a speed between 1,800 to 2,200 RPM), or similar. The diesel engine1512may be operatively coupled to the electric generator1514to supply electrical power to multiple electric drivers that power one or more auxiliary equipment such as cooling fans and lube oil pumps. Examples of a suitable electric generator include a Caterpillar Model SR4 200 KW, a Kato 200 KW Model A250180000, and the like. In some examples, the electric generator may be configured to provide 230/240-volt, 3-phase power or 460/480-volt, 3-phase power to individual variable frequency drives (VFDs)1504to power various motors1506of the auxiliary equipment. The VFD1504may include a full wave three-phase rectifier configured to convert incoming three-phase AC voltage to a desired DC voltage through a plurality (e.g., 9) of silicon controlled rectifiers (SCRs) or diodes. This DC voltage may then power those of the motors1506that are DC motors. Alternatively, the generated electrical current may be sent through an inverter at the prescribed voltage and synthesized sine wave frequency such that the VFDs may selectively control the operation of AC motors. This may be by the providing prescribed voltage and synthesized sine wave frequency the VFD selectively controls the speed and direction of the AC motors. In some examples, the VFDs may be configured to directly supply AC power to the AC motors, thereby eliminating the use on an external inverter. One example of a suitable VFD with connections to an AC motor is depicted inFIG.16. Examples of suitable VFDs include a Delta #CP 2000 VFD rated for 230 or 460 VAC, max power 1 to 536 HP, a Danfoss #130B0888 FC301 460V 3-phase, A Danfoss Vacon 100X, and the like. The VFDs1504may power the motors1506of various auxiliary equipment1520, the operation of each of which may add a load onto the electric power arrangement1500. Examples of various auxiliary equipment and respective approximate loads include:lube oil pump to the gearbox (1 HP)cooling fan to gearbox lube oil pump (15 HP)lube oil pump to the power end (15 HP)cooling fan to the power end lube oil pump×2 (15 HP each)cooling fan to the CAT C9 engine (10 HP)CAT C9 engine air cooling fan (10 HP)screw type air compressor to provide 150 pounds per square inch (PSI) air for fuelequipment intensifier to amplify to >200 PSI (7.5 HP) with air dryer (0.75 HP)greater equipment for the fracturing pump (0.25 HP)air intake blower fan motors×2 (40 HP each)GTE controller (1 HP)hydraulic starter pump equipment (60 HP)turbine lube cooling fan (4 HP)telescope exhaust winch×2 (1 HP each)master PLC for VFD/electric generator (2 HP)Total 236.5 HP/176 kW Each auxiliary equipment may add a horsepower drag on the overall electric power arrangement1500, and this drag may depend on characteristics of the auxiliary equipment. As suggested above, in some examples, the electric power arrangement1500may be more efficient with finer control of cooling and lubrication through feedback loops continuously monitored by processing circuitry such as a programmable logic controller (PLC). Examples of suitable controllers include a Parker IQAN™ controller, a Danfoss Plus+One® controller, or a custom process controller. In some examples, the electric power arrangement1500may also be powered by shore power1516through a separate connection to an external source of electric power. If using shore power, a selectable switch may be configured to selectably separate the electric generator1514from the shore power. In some examples, the electric power arrangement may include or be connected to a battery bank1518that may supply power in the case of diesel engine failure or shore power failure. Further consider examples of the system1100inFIGS.11-14in which the hydraulic fracturing units are connected to a power arrangement300configured to power the respective auxiliary equipment220across hydraulic fracturing units102. Also consider a particular example in which the system includes seven hydraulic fracturing units. Taking into account efficiency of the electric generator1514(commonly 80%), a minimum of 300 HP may be distributed per hydraulic fracturing unit. The total demand of the hydraulic fracturing units may depend on how many are rigged up. Further including backside equipment, the electric generator may power the following with respective approximate loads:hydraulic fracturing units (×7)=1655.5 HPchemical unit=107 HPhydration unit=665 HPsand tanks=750 HPblender=1433 HPdata center=500 HP The total horsepower supplied may be approximately 5110 HP (3806 kW). In the case of an electric generator1514driven by a GTE, one example of a suitable GTE is a Vericor TF50 turbine with a rated to 5600 HP (4200 kW). FIG.17is a block diagram a particular hydraulic power arrangement1700that in some examples may correspond to hydraulic power arrangement500shown inFIG.5. As shown, the hydraulic power arrangement includes an electric motor1710such as a 300 HP electric motor coupled to a module hydraulic pump drive1714with multiple (e.g., four) output gear shafts. The number of module hydraulic pump drives and output gear shafts may be varied to suit a particular application. Examples of a suitable electric motor include a Grainger 300 HP fire pump motor (460 V, 3-phase, 1780 RPM), a Baldor 300 HP motor (460 V, 3-phase, 1780 RPM), or the like. One example of a suitable module hydraulic pump drive is a Durst hydraulic pump drive gearbox #4PD08. The module hydraulic pump drive1714may power auxiliary equipment1720though motors and hydraulic pumps1712, which may be coupled to the module hydraulic pump drive individually or in tandem. In this regard, the hydraulic pumps may be configured to supply hydraulic fluid to corresponding hydraulic motors of various auxiliary equipment. These again may power auxiliary equipment such as cooling fans and lube oil pumps. Examples of various auxiliary equipment and respective approximate loads include:lube oil pump to the gearbox (1 HP)cooling fan to gearbox lube oil pump (8 HP)lube oil pump to the power end low pressure (11 HP)lube oil pump to the power end high pressure (18 HP)cooling fan to the power end lube oil pump (40 HP)greater equipment for the fracturing pump (1 HP)Turbine Fuel Pump (1.5 HP)Turbine Washing System (1 HP)Turbine/Gearbox/Hydraulic Cooler Fan (40 HP)Air exchange Fans (10 HP)Hydraulic Pump for Turbine Starter, Lid openings, Compressor etc (70 HP)Total 201 HP/150.37 kW This hydraulic power arrangement1700does not rely on a diesel engine but instead an electric motor that may operate off shore power from an external source of electric power that may supply power to multiple units on a jobsite, thereby eliminating at least several components that may be required for a diesel engine (e.g., a fuel pump, an air compressor, an engine cooling fan). FIG.18is a block diagram another particular power arrangement1800that may be connected to a powertrain1802that corresponds to powertrain208. As shown, the powertrain includes a housing with a GTE1810coupled to a turbine gearbox1816(reduction transmission) connected to a drive shaft1818, which, in turn, may be connected to the pump such as via an input shaft or input flange of the pump. The hydraulic power source includes a plurality of PTOs1804connected to the turbine gearbox, and at least one of the PTOs may be connected to an alternator1806or other electric generator. The alternator may be configured to generate electric power from which auxiliary equipment may be powered, and any unused electric power may be feedback to an external source such as the utility power grid. In some examples, the alternator1806may be engaged with or disengaged from the PTO1804via a hydraulic or pneumatic clutch to allow the GTE1814to direct more power through the drivetrain and into the pump if needed. When disengaged from the PTO, the auxiliary equipment may be powered from shore power connections and other generated grid power. When the alternator is engaged with the PTO, as well as feeding auxiliary equipment such as cooling fans and compressors, an uninterrupted power source (UPS)1808may be constantly charged during pumping operations. This UPS may be used to solely drive a hydraulic pump that will be used to start the GTE by feeding hydraulic power to the motor starter. An active front end (AFE)1810may be placed on the two outputs of the alternator1806to change AC voltage to DC.FIG.19illustrates one example of a suitable AFE. As shown, the AFE may include IBGTs (insulated bipolar gate resistors), which may ensue that harmonics and other power sent through the AFE are dampened and power efficiency is increased. As well as treating alternator power, another AFE may also treat raw shore power coming into the grid in the same way. FIG.20is a flowchart illustrating various operations in a method2000of fracturing a well, according to various example implementations. The method includes arranging one or more hydraulic fracturing units102,702, as shown at block2002. Each hydraulic fracturing unit includes a reciprocating plunger pump206configured to pump a fracturing fluid, a powertrain208configured to power the reciprocating plunger pump, and auxiliary equipment220driven to support operation of the hydraulic fracturing unit including the reciprocating plunger pump and the powertrain. The method includes arranging one or more electric power arrangements400to power the auxiliary equipment, as shown at block2004. And the method includes operating the powertrain to power the reciprocating plunger pump to pump the fracturing fluid, and the electric power arrangement to power the auxiliary equipment, as shown at block2006. FIG.21is a flowchart illustrating various operations in a method2100of fracturing a well, according to various other example implementations. The method includes arranging one or more hydraulic fracturing units102,702, as shown at block2102. Each hydraulic fracturing unit includes a reciprocating plunger pump206configured to pump a fracturing fluid, a powertrain208configured to power the reciprocating plunger pump, and auxiliary equipment220driven to support operation of the hydraulic fracturing unit including the reciprocating plunger pump and the powertrain. The method includes arranging one or more hydraulic power arrangements500,600to power the auxiliary equipment, as shown at block2104. And the method includes operating the powertrain to power the reciprocating plunger pump to pump the fracturing fluid, and the hydraulic power arrangement to power the auxiliary equipment, as shown at block2106. As described above and reiterated below with further example implementation details, various example implementations are disclosed herein that provide power arrangements and methods for powering of auxiliary equipment onboard a hydraulic fracturing unit such as a DDT hydraulic fracturing unit or trailer. The auxiliary equipment include, for example, cooling of process fluids through heat exchangers, pumping equipment, compressor units, winches and linear actuators, electrical control equipment, heats/coolers and hydraulic equipment. The power arrangements of example implementations may be configurable and may be adjusted to suit the needs of each individual scenario and situation. Some example implementations of a power arrangement include an engine or prime mover onboard the gooseneck area of a GTE-driven hydraulic fracturing unit. The engine/prime mover may be connected to an electric power generator such as a PM motor or a hydraulic pump drive with one or more pumps. Some example implementations include a diesel reciprocating engine onboard the GTE-driven hydraulic fracturing unit, and other example implementations includes an electric motor in place of the diesel engine. The location of the engine/motor may be the gooseneck area of a trailer, but the design of the trailer may permit installation of the engine/motor on the rear axles of the trailer. In examples including the diesel engine, it may be equipped with supporting equipment such as fuel reservoirs, coolant reservoirs, battery banks, diesel exhaust fluid tanks and cooling fans. The cooling fan on the diesel engine may be supplied by the engine manufacturer and mounted from a PTO located on the engine or it may be made external and powered from the hydraulic power network coming from the hydraulic pump drive. In another implementation, the diesel engine may be replaced with an electric motor that when installed is accompanied by electric switch gear that houses overload protection as well as a form of isolating the electric motor. Directly mounted from the diesel engine may be the hydraulic pump drive, which may be connected to the electric motor in another implementation. The hydraulic pump drive may have a female spur shaft connection that is installed onto the diesel engine or electric motor, and the two components may be secured via a bell housing that connects a face of the engine/motor to a face of the hydraulic pump drive. Once installed the hydraulic pump drive may be configured to house up to four pumps but will be rated by the total amount of horse power and torque it may yield at each output gear. Depending on the application, the use of a large displacement single pump directly coupled to the diesel engine may be beneficial. But there may be equal portion of components over the trailer that are operating at different pressures, such as a compressor and fans that operate at a flow that will generate 2000 PSI, and the pumps may operate at 3000 PSI at rated flow. Therefore, a variable displacement hydraulic pump with a compensator setting of 2000 PSI, and another pump with a compensator setting of 3000 PSI, may meet pressure requirements of each circuit bearing in mind that the output flow rate of each pumps should meet the flow demand from all components. Depending on the configuration of pumps there may be multiple hydraulic reservoirs installed on the hydraulic fracturing unit that would allow for each individual pump installed on the hydraulic pump drive to draw fluid from. This may mean that a pump with a greater suction vacuum would not take away fluid from a pump with a small displacement therefore a smaller suction pressure. Alternatively pump suction lines may be positioned in a way this does not happen, but the size of the reservoir and mounting location of the reservoir dictate this. The space taken up by the hydraulic reservoir may depend on flow demand within the auxiliary equipment. The dwell time for fluid may be greater in the individual or group of reservoirs due to the hydraulic power network being open circuit, meaning that the displaced fluid from the pump may go to the desired component and then return to tank opposed to returning to the pumps suction side. The hydraulic power network coming from the hydraulic pump drive may be equipped with filtration in the form of single or double housings that ensure fluid cleanliness is maintained to the best industry standard that is usually dictated by the International Organization for Standardization (ISO) fluid cleanliness classification. A diesel engine directly coupled to a hydraulic pump drive that is installed with hydraulic pumps may allow for great versatility. The adjustment of pump pressure and flow settings may allow the pumps to operate at their maximum efficiency while still ensuring they meet the power demands of the auxiliary equipment. Working in conjunction with the hydraulic pumps may be hydraulic directional control valves that isolate fluid going to individual circuits, and when actuated, allow a valve spool to shift and direct flow through the ports. In the case of hydraulic motors driving fluid pumps and fans, these components may be controlled to operate in a single direction to avoid damage to pumps and mis-operation of fans. This may be done by selecting a directional control valve with a closed center and two positions. In a de-energized state there may be no flow through the valve, resulting in the pump swash plate to move to the neutral position and stop displacing fluid. When operated via an electric signal energizing the solenoid from an electric control system, or commonly referred to as a supervisory control system (SCS), flow may be allowed to pass through the control valve to the designated auxiliary equipment that may operate a hydraulic motor. Return fluid may also be plumbed back to the hydraulic control valve and passed to a return line where it may be diverted back to the hydraulic reservoir. The control valves may be installed in multiple valves assemblies, commonly referred to as a “valve bank.” Another part of the hydraulic power arrangement may be cooling circuits. The operation of hydraulic power networks may generate heat as the fluid flowing through different orifices, and the resulting pressure drop yields heat into the fluid that may not only degrade fluid lubrication properties but also cause problems to the components being operated with the fluid. To mitigate this, hydraulic cooling circuits may be installed that are activated by thermostatic control valves. When the fluid gets too hot, the valve may open and diverts fluid though a fan driven heat exchanger ensuring that its cooled prior to returning to the reservoir and being introduced back into the hydraulic power network. The diesel engine and hydraulic package may be configured to easily fit onto the gooseneck of a standard hydraulic fracturing unit while still ensuring space for additional components such as reservoirs, heat exchangers and compressors. Hydraulic pumps installed from the hydraulic pump drive or directly from the engine are often very versatile. Ensuring that the flow requirements may be met, the pumps pressure compensator setting, as well as the introduction of load sensing, may ensure that only the required amount of power is drawn from the hydraulic pump. This may mean that the engine is operated at the power required, and that wasted energy and fuel is eradicated, thereby improving efficiency. The complexity of an individual hydraulic power network is not high, and the introduction of a hydraulic pump drive with multiple individual network branches may still maintain a simple approach without the need to interface all pumps into a single common pressure line. The versatility of adding hydraulic pump drives with different output gears while still maintaining the same circuitry in place may be a benefit of a driven hydraulic network branch and allow for expansion in circuitry without the need to perform complex adjustments. Operation of a circuit during hydraulic fracturing may be as follows. The SCS may operate from a battery storage device, which may be charged from an alternator or shore power provided to the implementation inclusive of an electric motor driving the hydraulic power network. The SCS may interface with the diesel engine through the engines electric control module (ECM), and from this, the engine may be given start, stop or throttle commands. Engine equipment information may also be sent through J1939 communication protocol. During startup of the hydraulic fracturing unit, the diesel engine may be sent a start command and reach idle speed; or in another example implementation, electric power brought onboard may enter a VFD. The SCS may send a digital output to the drive to start up. In addition to that digital signal, an analog signal in the state of 4-20 mA or 0-10V may be used to control the speed. The SCS may command the prime mover on the diesel engine to then go to a run speed which is typically 1900 RPM for most systems but could be as high as 2100 or as low as 1700 RPM. This speed may allow the hydraulic power source to operate at maximum power output and begin supplying flow into the hydraulic power network. The directional control valves may then be operated in a sequence ensuring that all pre-conditions are met before bringing the turbine engine online. When the fuel and lubrication pumps are operating within the correct parameters, the GTE start motor may be operated. This axial motor may be installed on a gearbox or other transmission toward a cold end of the turbine engine, and it may receive hydraulic flow. When the GTE reaches an idle speed, a sprag clutch in the turbine starter motor assembly may disengage, allowing combustion within the turbine combustion chamber to maintain the turbine speed. Upon reaching the idle speed, a signal may be removed from the hydraulic control valves to halt fluid to the starter motor. The hydraulic power arrangement may then operate the turbine engine and pump auxiliary equipment to distribute hydraulic flow through the control valves as per logic programmed into the SCS. As with startup of the diesel engine or operation of the electric motor, the SCS may be responsible for sending shutdown signals to either the diesel engine's ECM or electric motor frequency drive. In other example implementations, the hydraulic power arrangement may be replaced with an electric motor such as a PM motor that is directly coupled to the engine output shaft and connected to the engine housing via a bell housing adapter. However, a splined coupling may interface the two shafts, and a coupling may connect these splined adapters together. The PM motor may operate at an optimal speed of 1900 RPM to generate 500 VAC power. At this speed and power generation, an electric generator may yield a power factor of 0.93 making the generator highly efficient. The electric generator may also include a cooling circuit that is operable between 5-10 gallons per minute (GPM) and acts as a heat exchanger through the generator ensuring that the temperature on the generator winding does not exceed 175 degrees Celsius. A small pump to circulate this fluid may be first driven from battery storage device until the electric generator comes online and begins to re-charge the battery storage device and then power its own cooling pump. Coming from the generator may be the electric conditioning station that may also be located on the gooseneck in a water and dust proof IP66 enclosure. A cable carrying three-phase power may enter the enclosure into a main isolation breaker with overload protection, and from this, the power cable may be run into an AFE drive that may condition the signal into a DC voltage. Control of this AFE may be through the SCS, and communication may be carried out via modbus protocol. Downstream of the AFE may be a main DC bus bar that may hold the electric potential to distribute power to each individual control circuit around the hydraulic fracturing unit. From the bus bar there may be an individual circuit protection breaker for each control circuit that may be equipped with overload protection. In the event the current drawn from the motor in the control circuit is too great, the overload protection may trip the breaker resulting in power loss to that circuit and protection of all components in that circuit. From these individual circuit breakers, armored and shielded cables may then leave the enclosure through bulkhead connections equipped with explosion proof glands and assembly methods that ensure the integrity of the main switch gear assembly may be protected from potentially combustible gases. The cables may be secured in a cable tray that may then run to areas in which the electric motors may be in place. Prior to terminating the electric supply cables to the motor, the cables may first be terminated to an inverter drive that may convert the DC voltage into an AC voltage. The benefit of this may be the ease of sourcing AC electric motors and their lower capital costs. The inverter may condition the power coming in and leaving the drive. The inverter may also allow for proportional speed control of the motor and soft start functioning of the motor to reduce a current rush into the motor potentially tripping any circuit overload protection in the drive or back at the main isolator coming from the common bus bar. The electric motors connected to the electric drives may be used in place of hydraulic motors as detailed in other example implementation but may still be fluidly connected to the driven equipment such as pumps, fans, compressors with the use of couplings and bell housing adapters. Other driven equipment may be driven with the use of electric motors and are contemplated herein. A method of operation of the power arrangement of some examples may be as follows. The engine may be brought online in a similar manor to the previously described implementation in which the SCS may send a start signal to the diesel engine ECM via J1939 communication protocol. The engine may be brought online to a speed of 1900 RPM, at which point the electric generator may be producing 500 VAC electric power with the electric potential of up to 223 KW. The alternating current power form the electric generator may enter the electric conditioning assembly including the main isolator and the AFE rectifier that may convert the power to DC and distribute it over the electric bus bar. Current may be then able to flow into the main isolator for each electric circuit. The current may then flow around the hydraulic fracturing unit via the correctly sizes armor shielded electric cable into the inverter drive. The inverters may be networked and communicated with from the SCS. The SCS may function the inverter drive and alter the frequency in which the IBGTs of the AFE sequence, which may result in the frequency leaving the drive to the motor to be controlled, and thereby controlling the speed of which the motors turns. The power arrangement of these example implementations may allow for very accurate control of the individual circuitry. The analog signals to the drives may ensure that the frequency provided to the electric motors allows for exact RPMs to be met within 5-10 RPM tolerance. Electric motors may also provide a robust option for driving pumps and other auxiliary equipment. The lack of potential fluid contamination or fluid degradation usually allows these motors to stay in service longer ensuring that load bearings are greased and correct mounting of the motor may be performed. This implementation to drive auxiliary equipment of the hydraulic fracturing unit with electric motors may also provide benefit from lack of fluid travelling the entirety of the hydraulic fracturing unit, which may be susceptible to pressure drops and leaks. As previously mentioned, the ability to share generated power may be a benefit of the diesel engine and generator set up. For example, if ten hydraulic fracturing units are on location, and each generator produces more power than may be required on the individual hydraulic fracturing unit, a shared power configuration could see a portion of the ten hydraulic fracturing unit gen-sets taken offline and the remainder of the hydraulic fracturing units providing all hydraulic fracturing units with the total amount of electric energy required. Another example implementation of a method to power auxiliary equipment onboard hydraulic fracturing units may utilize the GTE transmission and include PTOs on the transmission to power a smaller electric generator and a single multistage pump. In some of these examples, a transmission such as a gearbox with a single input and output shaft may be modified to account for two additional PTOs positioned either side of the main output shaft or flange. These PTOs may be equipped with clutches that may be operated either pneumatically or hydraulically (or electrically in other example implementations). As well as the installation of the transmission with the PTOs, additional equipment may be installed onto the GTE-driven hydraulic fracturing unit to ensure that a controlled startup may be performed to get to a point where it may be self-sustained from its own operation. Taking this into account, a battery bank with one or more high-powered lithium ion batteries may be used to provide the starting power for onboard auxiliary equipment such as lube and fuel pumps as well as powering the electric motor that may be coupled to the GTE starter gear. Once the GTE is at running speed and there is motion at the output shaft, the clutches may be engaged to allow for the pumps and electric generator to receive torque and motion from the transmission and start to displace fluid and generate power. A single pump may address the needs of the reciprocating fracturing pump, and the single pump be a multistage pump that allows fluid to enter both low and high pressure sides of the pump. In other example implementations, the electric generator installed onto the diesel engine may supply enough power to all of the onboard auxiliary equipment. This may be not feasible when using a PTO from the transmission due to the footprint available and the large cantilever loading from the transmission as it may already support the mass of the GTE. Therefore, by taking away the reciprocating pump lube power requirements from the total KW load, there may or may not be use of a smaller generator capable of driving small motors coupled to fans that could range from 1 to 5 HP, as well as low pressure low flow fuel pumps and transmission lube pumps. As in other implementations, the SCS may be powered from a separate battery bank but may still allow for generated power to replenish the battery charge when operational. The remaining auxiliary equipment to be powered from the smaller generator coupled to the transmission may follow the same assembly methodology as stated above with respect to an earlier example implementation. According to these more recently-described example implementations, a method of operation may be as follows. The SCS may be online and command the GTE's primary auxiliary equipment to come online, which may result in fuel pumps and lube pumps to start. The GTE starter motor may then be functioned, allowing the GTE to reach an idle speed, after which the electric motor coupled to the starter gear may be disengaged and its power may be isolated. Once the power output shaft is functioned, and the GTE torque and power are transferred to the transmission, the clutches may be operated allowing the multistage pump and electric generator to be engaged and start rotating. The power from the electric generator may be then converted to DC through an AFE rectifier as described above, and distributed over a common DC bus. The power may be then distributed over the hydraulic fracturing unit and sent to drives that are controlling the speed of electric motors. This application is a continuation of U.S. Non-Provisional application Ser. No. 17/976,095, filed Oct. 28, 2022, titled “POWER SOURCES AND TRANSMISSION NETWORKS FOR AUXILIARY EQUIPMENT ONBOARD HYDRAULIC FRACTURING UNITS AND ASSOCIATED METHODS,” now U.S. Pat. No. 11,629,584, issued Apr. 18, 2023, which is a continuation of U.S. Non-Provisional application Ser. No. 17/555,815, filed Dec. 20, 2021, titled “POWER SOURCES AND TRANSMISSION NETWORKS FOR AUXILIARY EQUIPMENT ONBOARD HYDRAULIC FRACTURING UNITS AND ASSOCIATED METHODS,” now U.S. Pat. No. 11,530,602, issued Dec. 20, 2022, which is a continuation of U.S. Non-Provisional application Ser. No. 17/203,002, filed Mar. 16, 2021, titled “POWER SOURCES AND TRANSMISSION NETWORKS FOR AUXILIARY EQUIPMENT ONBOARD HYDRAULIC FRACTURING UNITS AND ASSOCIATED METHODS,” now U.S. Pat. No. 11,236,739, issued Feb. 1, 2022, which is a divisional of U.S. Non-Provisional application Ser. No. 16/946,079, filed Jun. 5, 2020, titled “POWER SOURCES AND TRANSMISSION NETWORKS FOR AUXILIARY EQUIPMENT ONBOARD HYDRAULIC FRACTURING UNITS AND ASSOCIATED METHODS,” now U.S. Pat. No. 10,989,180, issued Apr. 27, 2021, which claims the benefit of and priority to U.S. Provisional Patent Application No. 62/899,971, filed Sep. 13, 2019, titled “AUXILIARY DRIVE SYSTEMS AND ALTERNATIVE POWER SOURCES,” the entire disclosures of each of which are incorporated herein by reference. Many modifications and other implementations of the disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated figures. Therefore, it is to be understood that the disclosure is not to be limited to the specific implementations disclosed herein and that modifications and other implementations are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. | 55,630 |
11859483 | Like reference symbols in the various drawings indicate like elements. DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS To aid understanding, this document is organized as follows. First, to help introduce discussion of various embodiments, a selective overbalanced perforation and injection system for wellbore completion is introduced with reference toFIGS.1A-2. Second, that introduction leads into a description with reference toFIGS.3A-3Fof some exemplary methods of selective clusters perforation. Third, with reference toFIG.4, an exemplary method is described in application to exemplary selective overbalanced perforation and injection. Fourth, with reference toFIGS.5-7, the discussion turns to exemplary embodiments that illustrate a pressure isolation device. Fifth, this disclosure turns to a discussion of breakdown pressure in wellbore completion with reference toFIG.8. Finally, the document discusses further embodiments, exemplary applications and aspects relating to selective overbalanced perforation and injection. FIG.1AandFIG.1Bdepicts an exemplary selective overbalanced perforation and injection (SOPI) system100in an illustrative use-case scenario. In this illustrative example, a wellbore casing105(e.g., casing an oil well) is disposed in a geological formation110(e.g., at least partially in oil bearing strata). As shown inFIG.1A, a previous perforation operation (e.g., using a perforation gun) has been performed to form completed perforations115. In the depicted example, the completed perforations115have been stimulated to form a stimulated region120in the geological formation110. A frac plug125, in this example, was set in the wellbore casing105to isolate the completed perforations115with upstream of the wellbore casing105. As an illustrative example, the completed perforations115may have been a last cluster of perforations in a previously fractured stage. The previously fractured stage, as depicted is fluidly isolated by the frac plug125(e.g., carried and set using a bottom hole assembly) before beginning a next stage. The SOPI system100includes an overbalancing bottomhole assembly (OBBHA)130. As shown inFIG.1A, the OBBHA130is positioned at a target perforation portion135of the wellbore casing105. As depicted, the OBBHA130generates (e.g., detonates, ‘shoots open’) a plurality of new perforations140at the target perforation portion135. In some examples, a pressured hydraulic fluid145is applied after the new perforations140. For example, the pressured hydraulic fluid145may be applied to perform a skin repair operation for the new perforations140. In some implementations, the pressured hydraulic fluid145may be a non-particulate fluid. In some examples, the pressured hydraulic fluid145may be configured to have a skin-repairing effect for the newly formed perforations140. In this example, the OBBHA130includes a pressure isolation device (PID)150. In some implementations, the PID150may be activated to isolate the new perforations140with other perforations downstream (e.g., at least partially stimulated perforations, such as having reached breakdown pressure and/or having performed skin repair operations but before final completion such as fracturing) such that the pressured hydraulic fluid145is not in fluid communication with the prior perforations115. In some implementations, a completion of skin repair corresponding to the new perforations140may be determined by the pressure hydraulic fluid145reaching a geological breakdown pressure of the material surrounding the new perforations140. For example, the pressured hydraulic fluid145may increase in flow rate to increase pressure to stimulate the new perforations140. In some examples, after the geographical breakdown pressure is reached, a pressure of the pressured hydraulic fluid145may drop despite increase in flow rate. After target skin repair operations of the new perforations140are completed by the pressured hydraulic fluid145, as shown inFIG.1B, the OBBHA130may be moved to another portion155upstream of the wellbore casing105to form a second set of new perforations160. In some implementations, the OBBHA130may repeat this process until each distinct isolatable portion of perforations in a selected portion in the wellbore casing105has had target skin repair operations completed (e.g., breakdown pressure individually reached for each isolatable portion). in some embodiments, for example, the OBBHA130may be removed from the wellbore before final completion of the stage (e.g., including the multiple perforation clusters) as a group (e.g., all perforation clusters above the frac plug125). For example, the OBBHA130may be removed before fracturing fluid is pumped into the wellbore. Accordingly, the SOPI system may advantageously avoid damages of the OBBHA130by sand, stone, or other particles that may be used in the fracturing fluid. Such embodiments may, for example, advantageously prevent seizing of the OBBHA130in the wellbore due to sand-locking (accumulation of particulates on uphole surfaces of the OBBHA130which ‘jam’ the OBBHA130in the wellbore casing105when trying to withdraw the OBBHA130). Therefore, such embodiments may advantageously reduce cost of recovering the OBBHA130and/or clearing obstruction of the wellbore casing105. In some implementations, to complete and stimulate a target portion of a wellbore using the SOPI system100within the wellbore casing105, the target portion may be divided into N distinct portions along a length of the wellbore casing105. For each of the N distinct portions, for example, starting from the most downhole portion of the target portion, the OBBHA130may releasably fluidly isolate a currently operating portion from downstream such that the currently operating portion is fluidly isolated from substantially all downstream perforation clusters. Next, the OBBHA130may, for example, generate a cluster of perforations at the fluidly isolated portion. For example, the OBBHA130may include a perforation gun to shoot open the cluster of perforations at the fluidly isolated portion. After the cluster of perforations are formed, for example, a non-particulate skin-repairing fluid may be pumped from uphole at a pressure such that a breakdown pressure of a geological formation surrounding the casing at the plurality of perforations is exceeded. In some examples, once the breakdown pressure is exceeded, the OBBHA130may reestablish fluid communication between the currently operating portion and downstream or the wellbore casing105. After clusters of perforations have been formed at substantially all N distinctive portion, for example, the OBBHA130may be removed from the wellbore casing. In some implementations, completion operations may then be performed to complete openings of the geological formations through the perforations. FIG.2is a block diagram of an exemplary overbalancing bottomhole assembly (OBBHA)130using for the SOPI system100described inFIG.1. The OBBHA130is provided with the PID150. In the depicted example, the PID150is disposed between a series of perforation guns210and a frac plug setting tool215. As depicted, the frac plug setting tool215is coupled to the frac plug125. The frac plug125may, for example, be set in a wellbore casing to isolate a downstream section from an upstream section of the wellbore casing for perforation and/or injection. Each perforation gun210may, for example, have one or more (explosive) charges configured to be detonated by an activation signal. Each charge may, for example, be configured to exit the perforation gun210substantially radially and to pierce a wellbore casing, cement, surrounding geological formations, or some combination thereof. Accordingly, fluid communication may be advantageously provided between (fluid-bearing) geological formations and the wellbore. As depicted, the OBBHA130is further provided with depth correlation tool(s)225. The depth correlation tool(s)225may, for example, be configured to determine a position of the OBBHA130in the wellbore. In some examples, one or more operations of one or more components of the OBBHA130may be initialized at one or more (predetermined) depths based on a depth determined by the depth correlation tool(s)225. The OBBHA130is provided with a cable230. The cable230is coupled to the OBBHA130by a cable connection235. The cable connection235may, for example, also function as an emergency release (E-release) coupler. The cable230may, by way of example and not limitation, provide operating power, (electromagnetic) communication to and/or from at least one component of the OBBHA130and an operator(s) (e.g., at ground level), mechanical support and/or control, or some combination thereof. In some implementations, the perforation gun210alone may, for example, not sufficiently penetrate surrounding geological formations to provide fluid access between the wellbore and target geological formation (e.g., petroleum bearing formations). In some implementations, to stimulate the perforated holes generated by the perforation gun210, access-enhancing fluids (e.g., water, acids, solvents, gasses, hydrocarbons) may be pumped into the wellbore casing105to pressurize the wellbore. In some implementations, a number of perforations to be exposed for pressurization at a time may be selected. Exposing a large number of perforations to pressurization of the wellbore may, for example, allow only some of the perforations to receive a disproportionate effect (e.g., enlarging the perforation in the casing and/or cement and/or a corresponding channel in the geological formation). Accordingly, exposing a large number of perforations and/or too many clusters of perforations to pressure simultaneously may have little to no effect on stimulating (e.g., inducing fluid communication through) some or most of the perforations. On the other hand, for example, exposing a small number of perforations may increase a success rate of the stimulating effect. However, the time used for exposing a small number of perforations at a time may significantly increase time and cost for fracturing and/or perforating a same length of the wellbore. In various embodiments the PID150may be selectively activated to fluidly isolate a previous perforation(s) from a target perforation (cluster). Accordingly, the target perforation(s) may be selectively overbalanced (e.g., pressurized over the pressure in a subterrain hydrocarbon bearing rock's pressure) or underbalanced (e.g., pressurized under the pressure in the subterrain hydrocarbon bearing rock's pressure). The target perforation(s) may, therefore, be precisely targeted to ensure the pressurization and/or access fluid may reach target perforation(s) and not be diverted into open perforation(s) below. Accordingly, the SOPI may advantageously efficiently stimulate each new cluster of perforations before creating a subsequent cluster. Various embodiments may advantageously allow a higher percentage (e.g., substantially all) perforation clusters shot to be stimulated to effectively provide fluid communication between the corresponding geological formation(s) and the wellbore, as compared to shooting multiple (e.g., all) perforation clusters before pressurization. In some implementations, the SOPI system may advantageously reduce and/or eliminate costs of rework and/or remediation (e.g., which may be $10,000/hour or more). In various embodiments the perf-cluster (pre-) stimulation (e.g., skin repair, partial completion) may be advantageously performed, for example, without removing the OBBHA130. Accordingly, each cluster of perforations may, for example, be individually (e.g., per cluster) at least partially stimulated in rapid succession by selective fluid and/or pressure isolation of each new cluster from previously formed perforations by the PID150. FIG.3A,FIG.3B,FIG.3C,FIG.3D,FIG.3E, andFIG.3Fdepict the OBBHA ofFIG.2employed for SOPI in an illustrative wellbore casing. As depicted, the wellbore casing105may, for example, be a horizontal well (e.g., oil well, gas well). The well may, for example, be placed in a shale formation(s). As depicted inFIG.3A, the OBBHA130is disposed within the wellbore casing105. The OBBHA130may, by way of example and not limitation, be hydraulically pumped down into the wellbore casing105. In various embodiments, the OBBHA130may, by way of example and not limitation, be guided into the wellbore casing105by a pipe system (e.g., in addition to or in place of the cable230). In some implementations, the OBBHA130may be positioned at a current position based on a depth guidance provided by the depth correlation tool(s)225. As shown inFIG.3B, the wellbore casing105include a series of previous perforation clusters305. For example, the perforation clusters305may be formed through previously completed perforation and stimulation operations. In this example, the frac plug setting tool215set the frac plug125to separate the previous batch of perforation clusters305from a current batch of perforation clusters to be created. In some examples, the OBBHA130may be pulled upstream to a first selected portion310for generating the first cluster of perforation. As shown inFIG.3C, the OBBHA130is positioned in the wellbore casing105position such that the PID150proximally downstream of the first selected portion310to be created. In this example, the PID150is activated to fully or at least partially isolate a fluid communication between the first selected portion and downstream. In some implementations, the wellbore is pressured up by pumps on surface at this step. As depicted inFIG.3D, a first cluster of perforations315have been formed in the wellbore casing105by the perforation gun210. In some implementations, when the first cluster315is perforated, stimulation fluid (e.g., acid, other fluid) may subsequently be pumped into the cluster. In some examples, the pumping fluid may provide diagnostic functions. In some implementations, by selectively isolating clusters to be injected, diagnostic pumping tests may be performed. Some examples of diagnostic pumping test may include step-up rate tests, step-down pump rate tests, and Diagnostic Fracture Injection Tests (DFIT). In some implementations, the OBBHA130may be used to perform real-time diagnostics to determine whether more perforations are needed in the current cluster, for example. After the first cluster315is completely perforated, the PID150is deactivated and the OBBHA130is moved to a second selective position320as shown inFIG.3E. The PID150is then activated to seal against the wellbore casing105, as shown inFIG.3F, and a second perforation cluster325is formed. Accordingly, the PID150fluidly isolates the first perforation cluster315from the second perforation cluster325. For example, the second perforation cluster325may be selectively pressured (e.g., overbalanced) before and/or during and/or after shooting the perforation cluster. In some implementations, the selective pressure may be provided external to the OBBHA130from the surface. In some examples, the stimulation fluid may be pumped into the wellbore casing105to selectively stimulate only the second perforation cluster325before further perforation clusters are formed. Accordingly, the second perforation cluster325may be advantageously selectively targeted for stimulation to provide a desired level of fluid communication between the inside of the casing and the surrounding geological formation(s). In some implementations, the above processFIGS.3A-3Fmay be repeated to create the desired quantity of clusters within the target portion of the wellbore casing105. After the desired quantity of clusters is created, for example, the OBBHA130may be removed from the wellbore casing. For example, the wellbore casing is then ready to be hydraulically fracture stimulated. In some implementations, the hydraulically fracture stimulation process may include include fracturing (e.g., with acid and/or sand, with water, hydrocarbon or gases), and/or pumping below a fracturing gradient (e.g., matrix acidized). FIG.4depicts an exemplary method400of selective overbalanced perforation and injection. In the depicted method400, a target portion of the wellbore casing is divided402into N distinct portions. Next, a perforating tool string (e.g., the OBBHA130) is positioned405in a wellbore (e.g., the wellbore casing105). If previous clusters of perforations were made in the casing and stimulated410, then a frac plug is set415. If the frac plug is not a ball-in-place plug (or other mechanism which fluidly seals a lower portion of the casing from an upper portion)420, then a pressure isolation device (e.g., PID150) is activated425. If there are not previous stimulated perforation clusters410(e.g., in the current frac stage, in a first frac stage to isolate the current section from a toe of the well), then the PID is activated425. If there were previously stimulated clusters410and a ball-in-place frac plug (or other suitable sealing mechanism) was set420, or after activation425of the PID, then a pressure imbalance is generated430at least in the section of the casing which is to be perforated. Pressure imbalance may, by way of example and not limitation, be over balance or underbalanced. Accordingly, a target portion of casing for a next cluster (e.g., corresponding to one or more perforation guns) of perforations maybe advantageously fluidly isolated from downhole casing. For example, the target portion of casing may be selectively isolated from previously formed perforations. The previously formed may, perforations may, by way of example and not limitation, have been previously stimulated. In various embodiments the PID may be activated even if a frac plug was set and or previous perforations were not made. Accordingly, the target region may be advantageously isolated from a downhole region (e.g., to reduce time, stimulation fluid, and/or cost). Once the pressure imbalance is generated430, new perforations are shot435(e.g., by the perforation gun(s)210). Stimulation fluid is applied440to the new perforations. The new perforations may thereby be selectively stimulated by the fluid and/or pressure imbalance by being isolated from downhole regions and or perforations by the PID. In the depicted example, once the new perforations have been stimulated by applying fluid440and or pressure430, pumping diagnostics are performed445on the new perforations. If the pumping diagnostics445demonstrate the perforations are not open450, then steps440through450are repeated. Once the perforations are determined to be open450and if the PID was activated455, then the PID is deactivated460. In some implementations, by way of example and not limitation, steps445and/or450may be omitted. In the depicted example, if the PID was not activated455, or has been deactivated460, and if all clusters are not yet perforated in the current stage (e.g., in a current frac stage)465, then the perforating tool string is repositioned470and the steps425through465are repeated. Once the perforation clusters (e.g., all the perforation clusters to be made in the current stage465) are made in the current stage465, then the tool string is removed475from the wellbore. The (entire) wellbore may then be hydraulically fracture stimulated480through the perforations formed. In some implementations, by way of example and not limitation, steps470and/or repeating steps425-465may be omitted. Once the just formed perforations are fracture stimulated, if all fracture stages are not complete485, then steps405through485are repeated. Once all fracture stages are complete485, then the process ends. FIG.5depicts a first embodiment of an exemplary pressure isolation device (PID)500. In this example, the PID500includes a receiving module505and a sealing surface module510. The sealing surface module510includes sealing surfaces515. When the PID500is deactivated, the sealing surfaces are at positions520. In this example, when the PID is activated, the receiving module505and the sealing surface module510may both apply an opposite force (as shown by the big arrows) towards each other. In some implementations, the receiving module505may include a conical portion to receive the sealing surfaces515. In some examples, the forces may drive the sealing surfaces515to make contact with an inside wall to create an at least partially pressure seal. For example, the sealing surfaces515are driven to sealing positions525. In some examples, the force between the receiving module505and the sealing surface module510may be driven by electromagnetic forces. For example, the receiving module505and the sealing surface module510may include electromagnetic module that pull each other together when activated. In some implementations, the receiving module505and the sealing surface module510may include fluid hydraulic motors to generate the force. FIG.6depicts a second embodiment of an exemplary pressure isolation device (PID)600. The PID600includes a flexible cone605. For example, the flexible cone605may be an elastic diaphragm. In some implementations, the flexible cone605may expand when a fluid is, for example, pump in a direction as shown in arrows610as depicted. For example, the expanded flexible cone615may create at least partially a pressure seal to downstream of the wellbore casing105. In some examples, when pumping stops, the flexible cone605may return to the original position, reopening the fluid communication to downstream. The PID600also includes a burst disk620. In some implementations, the burst disk620may rupture by pressure or by electrical signal to allow an internal bypass when pulling the OBBHA130connected to the PID600out of the wellbore casing105. FIG.7depicts a third embodiment of an exemplary pressure isolation device (PID)700. The PID700includes a sealing module705with a sealing surface710. In a non-deployed mode, the sealing surface710is at a position A. In a deployed mode, a force715is applied in the direction of arrows, the sealing module705squishes the sealing surface710to position B against an inside wall of the wellbore casing105. For example, the sealing surface710at the position B may create a pressure seal or a partial seal. When the force715is removed, the sealing surface710may return to the position A. FIG.8is a diagram showing an exemplary pressure and time relationship800during cluster skin-repairing operations. For example, after a cluster of perforations are created, pumping of the access-enhancing fluid may increase initially a pressure within the wellbore casing105over time. As shown inFIG.8, the pressure may increase until a breakdown pressure is reached. After the breakdown pressure has been reached, the pressure decreases in this example. In some implementations, a pumping diagnostic module may use the pressure at various time after pumping detect whether a breakdown pressure805of the geological formation around the stimulating perforations is reached. Accordingly, in some implementations, environmental impact may be advantageously reduced in the fracture stimulation operations because the breakdown pressure805has been reached. Although various embodiments have been described with reference to the figures, other embodiments are possible. In some implementations, the SOPI system may manipulate a wellbore casing pressure into overbalanced, balanced, underbalanced to reservoir pressure or to fracturing pressure. For example, by manipulating the pressure in the wellbore where perforations are being made, the SOPI system100allows for the breakdown and fracture pressure to be exceeded at the instant of creating the access to the reservoir. Although an exemplary system has been described with reference toFIGS.1A-1B, other implementations may be deployed in other industrial, scientific, medical, commercial, and/or residential applications. In some implementations, the method400may include fine tuning of limited entry technique. For example, the method400may measure each cluster pressure profile individually. In some implementations, the method400may include measuring anisotropy or rock properties within an interval that is hydraulically fracture stimulated. In various embodiments, some bypass circuits implementations may be controlled in response to signals from analog or digital components, which may be discrete, integrated, or a combination of each. Some embodiments may include programmed, programmable devices, or some combination thereof (e.g., PLAs, PLDs, ASICs, microcontroller, microprocessor), and may include one or more data stores (e.g., cell, register, block, page) that provide single or multi-level digital data storage capability, and which may be volatile, non-volatile, or some combination thereof. Some control functions may be implemented in hardware, software, firmware, or a combination of any of them. Computer program products may contain a set of instructions that, when executed by a processor device, cause the processor to perform prescribed functions. These functions may be performed in conjunction with controlled devices in operable communication with the processor. Computer program products, which may include software, may be stored in a data store tangibly embedded on a storage medium, such as an electronic, magnetic, or rotating storage device, and may be fixed or removable (e.g., hard disk, floppy disk, thumb drive, CD, DVD). Although an example of a system, which may be portable, has been described with reference to the above figures, other implementations may be deployed in other processing applications, such as desktop and networked environments. Temporary auxiliary energy inputs may be received, for example, from chargeable or single use batteries, which may enable use in portable or remote applications. Some embodiments may operate with other DC voltage sources, such as a 9V (nominal) batteries, for example. Alternating current (AC) inputs, which may be provided, for example from a 50/60 Hz power port, or from a portable electric generator, may be received via a rectifier and appropriate scaling. Provision for AC (e.g., sine wave, square wave, triangular wave) inputs may include a line frequency transformer to provide voltage step-up, voltage step-down, and/or isolation. Although particular features of an architecture have been described, other features may be incorporated to improve performance. For example, caching (e.g., L1, L2, . . . ) techniques may be used. Random access memory may be included, for example, to provide scratch pad memory and or to load executable code or parameter information stored for use during runtime operations. Other hardware and software may be provided to perform operations, such as network or other communications using one or more protocols, wireless (e.g., infrared) communications, stored operational energy and power supplies (e.g., batteries), switching and/or linear power supply circuits, software maintenance (e.g., self-test, upgrades), and the like. One or more communication interfaces may be provided in support of data storage and related operations. Some systems may be implemented as a computer system that can be used with various implementations. For example, various implementations may include digital circuitry, analog circuitry, computer hardware, firmware, software, or combinations thereof. Apparatus can be implemented in a computer program product tangibly embodied in an information carrier, e.g., in a machine-readable storage device, for execution by a programmable processor; and methods can be performed by a programmable processor executing a program of instructions to perform functions of various embodiments by operating on input data and generating an output. Various embodiments can be implemented advantageously in one or more computer programs that are executable on a programmable system including at least one programmable processor coupled to receive data and instructions from, and to transmit data and instructions to, a data storage system, at least one input device, and/or at least one output device. A computer program is a set of instructions that can be used, directly or indirectly, in a computer to perform a certain activity or bring about a certain result. A computer program can be written in any form of programming language, including compiled or interpreted languages, and it can be deployed in any form, including as a stand-alone program or as a module, component, subroutine, or other unit suitable for use in a computing environment. Suitable processors for the execution of a program of instructions include, by way of example, both general and special purpose microprocessors, which may include a single processor or one of multiple processors of any kind of computer. Generally, a processor will receive instructions and data from a read-only memory or a random access memory or both. The essential elements of a computer are a processor for executing instructions and one or more memories for storing instructions and data. Generally, a computer will also include, or be operatively coupled to communicate with, one or more mass storage devices for storing data files; such devices include magnetic disks, such as internal hard disks and removable disks; magneto-optical disks; and optical disks. Storage devices suitable for tangibly embodying computer program instructions and data include all forms of non-volatile memory, including, by way of example, semiconductor memory devices, such as EPROM, EEPROM, and flash memory devices; magnetic disks, such as internal hard disks and removable disks; magneto-optical disks; and, CD-ROM and DVD-ROM disks. The processor and the memory can be supplemented by, or incorporated in, ASICs (application-specific integrated circuits). In some implementations, each system may be programmed with the same or similar information and/or initialized with substantially identical information stored in volatile and/or non-volatile memory. For example, one data interface may be configured to perform auto configuration, auto download, and/or auto update functions when coupled to an appropriate host device, such as a desktop computer or a server. In some implementations, one or more user-interface features may be custom configured to perform specific functions. Various embodiments may be implemented in a computer system that includes a graphical user interface and/or an Internet browser. To provide for interaction with a user, some implementations may be implemented on a computer having a display device, such as a CRT (cathode ray tube) or LCD (liquid crystal display) monitor for displaying information to the user, a keyboard, and a pointing device, such as a mouse or a trackball by which the user can provide input to the computer. In various implementations, the system may communicate using suitable communication methods, equipment, and techniques. For example, the system may communicate with compatible devices (e.g., devices capable of transferring data to and/or from the system) using point-to-point communication in which a message is transported directly from the source to the receiver over a dedicated physical link (e.g., fiber optic link, point-to-point wiring, daisy-chain). The components of the system may exchange information by any form or medium of analog or digital data communication, including packet-based messages on a communication network. Examples of communication networks include, e.g., a LAN (local area network), a WAN (wide area network), MAN (metropolitan area network), wireless and/or optical networks, the computers and networks forming the Internet, or some combination thereof. Other implementations may transport messages by broadcasting to all or substantially all devices that are coupled together by a communication network, for example, by using omni-directional radio frequency (RF) signals. Still other implementations may transport messages characterized by high directivity, such as RF signals transmitted using directional (i.e., narrow beam) antennas or infrared signals that may optionally be used with focusing optics. Still other implementations are possible using appropriate interfaces and protocols such as, by way of example and not intended to be limiting, USB 2.0, Firewire, ATA/IDE, RS-232, RS-422, RS-485, 802.11 a/b/g, Wi-Fi, Ethernet, IrDA, FDDI (fiber distributed data interface), token-ring networks, multiplexing techniques based on frequency, time, or code division, or some combination thereof. Some implementations may optionally incorporate features such as error checking and correction (ECC) for data integrity, or security measures, such as encryption (e.g., WEP) and password protection. In various embodiments, the computer system may include Internet of Things (IoT) devices. IoT devices may include objects embedded with electronics, software, sensors, actuators, and network connectivity which enable these objects to collect and exchange data. IoT devices may be in-use with wired or wireless devices by sending data through an interface to another device. IoT devices may collect useful data and then autonomously flow the data between other devices. Various examples of modules may be implemented using circuitry, including various electronic hardware. By way of example and not limitation, the hardware may include transistors, resistors, capacitors, switches, integrated circuits, other modules, or some combination thereof. In various examples, the modules may include analog logic, digital logic, discrete components, traces and/or memory circuits fabricated on a silicon substrate including various integrated circuits (e.g., FPGAs, ASICs), or some combination thereof. In some embodiments, the module(s) may involve execution of preprogrammed instructions, software executed by a processor, or some combination thereof. For example, various modules may involve both hardware and software. In an illustrative example, a wellbore completion method within a wellbore casing may divide a target portion of the wellbore casing into N distinct portions along a length of the wellbore casing. The method may insert a wellbore completion tool into the wellbore casing. The wellbore completion method may set a plug at a downstream boundary of the target portion such that the target portion may be fluidly isolated from other downstream clusters in the wellbore casing. For each of the N distinct portions, the method may, from a most downstream portion within the target portion, select the most downstream portion without perforation. The wellbore completion method may position the wellbore completion tool at the selected portion. The wellbore completion method may perform isolation operations to releasably fluidly isolate the selected portion from downstream such that the selected portion is isolated from substantially all downstream perforation clusters. The method may include generate a cluster of perforations at the fluidly isolated selected portion. The wellbore completion method may perform cluster skin-repairing operations by pumping externally to the wellbore completion tool, from upstream, a non-particulate skin-repairing fluid at a pumping pressure such that a breakdown pressure of a geological formation surrounding the wellbore casing at the cluster of perforations is exceeded. Upon the breakdown pressure being exceeded, the method may include reestablishing fluid communication between the selected portion and the downstream perforation clusters. After clusters of perforations have been formed at substantially all N distinctive portions, the wellbore completion method may include removing the wellbore completion tool from the wellbore. The wellbore completion method may include perform completion operations to complete opening of the geological formations through the generated clusters of perforations. The completion operations may further include pump a fracturing fluid at a pressure below the breakdown pressure. The cluster skin-repairing operations may include detect a drop in wellbore pressure while the pumping pressure is maintaining or increasing. The operations may determine whether the breakdown pressure is exceeded when the drop exceeds a predetermined threshold. After the isolation operations, the wellbore completion method may include selectively pressurize the fluidly isolated selected portion. The isolation operations may include pumping a fluid downstream against an isolation diaphragm such that the isolation diaphragm is releasably coupled to a wall of the wellbore casing. The isolation operations may include applying a force from a first sealing module to a sealing surface such that the sealing surface is releasably coupled to a wall of the wellbore casing. The isolation operations may include applying an opposite force from sealing module against a receiving module such that, a sealing surface is pressingly attached to a wall of the wellbore casing. The applied force may be electromagnetic force. The applied force may be at least partially generated by fluid hydraulics. In an illustrative example, a wellbore completion method within a wellbore casing may divide a target portion of the wellbore casing into N distinct portions along a length of the wellbore casing. The wellbore completion method may include insert a wellbore completion tool into the wellbore casing. The wellbore completion method may include, from a most downstream portion within the target portion, perform perforation operations for each of the N distinct portions. The method may include select the most downstream portion without perforation. The method may include position the wellbore completion tool at the selected portion. The wellbore completion method may include perform isolation operations to releasably fluidly isolate the selected portion from downstream such that the selected portion is isolated from substantially all downstream perforation clusters. The wellbore completion method may include generate a cluster of perforations at the fluidly isolated selected portion. The method may include perform a cluster skin-repairing operations by pumping, from upstream, a non-particulate skin-repairing fluid at a pumping pressure such that a breakdown pressure of a geological formation surrounding the wellbore casing at the cluster of perforations is exceeded. Upon the breakdown pressure being exceeded, the wellbore completion method may include reestablish fluid communication between the selected portion and the downstream perforation clusters, After clusters of perforations have been formed at substantially all N distinctive portions, the wellbore completion method may include remove the wellbore completion tool from the wellbore. The method may include perform completion operations to complete opening of the geological formations through the generated clusters of perforations. Before performing the perforation operations, the wellbore completion method may include set a plug at a downstream boundary of the target portion such that the target portion is fluidly isolated from other downstream clusters in the wellbore. The completion operations may include pumping a stimulation fluid at a pressure below the breakdown pressure. The pumping pressure may be provided external to the wellbore completion tool. The cluster skin-repairing operations may include detect a drop in wellbore pressure while the pumping pressure is maintaining or increasing. The cluster skin-repairing operations may include determine that the breakdown pressure is exceeded as a function of the drop exceeding a predetermined threshold. After the isolation operations, the wellbore completion method may include selectively pressurize the fluidly isolated selected portion. The isolation operations may include pumping a fluid downstream against an isolation diaphragm such that the isolation diaphragm may be releasably coupled to a wall of the wellbore casing. The isolation operations may include apply a force from a first sealing module to a sealing surface such that the sealing surface is releasably coupled to a wall of the wellbore casing. The isolation operations may include apply an opposite force from a sealing module against a receiving module such that a sealing surface is pressingly attached to a wall of the wellbore casing. The applied force may include electromagnetic force. The applied force may be at least partially generated by fluid hydraulics. A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made. For example, advantageous results may be achieved if the steps of the disclosed techniques were performed in a different sequence, or if components of the disclosed systems were combined in a different manner, or if the components were supplemented with other components. Accordingly, other implementations are contemplated within the scope of the following claims. | 41,033 |
11859484 | DETAILED DESCRIPTION Stratified fractured reservoirs may present wide permeability contrasts between different between different layers. When water is injected in these reservoirs, the fluids used will preferentially travel through the path of the least resistance of high permeability layers leaving other zones uncontacted by the fluids. Poor horizontal and vertical sweep efficiencies in stratified reservoirs may lead to low rates of oil recovery. Accordingly, a need exists for maximizing oil recovery is such stratified reservoirs. The present disclosure is directed to blocking the regions or layers of high permeability fractures in stratified reservoirs to improve the injectivity and oil recovery. In particular, in one aspect, embodiments disclosed herein relate generally to methods for enhancing the productivity of a subterranean wellbore through the use of responsive nanoparticles followed by in-situ acoustic wave generation to swell the nanoparticles in situ and block high permeability regions in different layers for enhanced sweep efficiency and better mobility control in stratified fractured reservoirs. According to one or more embodiments, responsive nanoparticles are injected in the reservoir and acoustic waves are used to swell these nanoparticles and block high permeability regions in different layers. More particularly, the method according to one or more embodiments may be used in a stratified reservoir having a first layer being located in a region of high permeability, a second layer being located in a region of medium permeability, and a third layer being located in a region of low permeability. The responsive nanoparticles may be used in compositions including the responsive nanoparticles and water. The responsive nanoparticles may include particles having an average or a mean particle size of about 1 nanometers (“nm”) to about 100 nm (e.g., about 5 nm to about 100 nm, about 10 nm to about 100 nm, about 20 nm to about 100 nm, about 30 nm to about 100 nm, about 40 nm to about 100 nm, about 50 nm to about 100 nm, about 60 nm to about 100 nm, about 70 nm to about 100 nm, about 80 nm to about 100 nm, about 90 nm to about 100 nm, 5 nm to about 95 nm, about 10 nm to about 95 nm, about 20 nm to about 95 nm, about 30 nm to about 95 nm, about 40 nm to about 95 nm, about 50 nm to about 95 nm, about 60 nm to about 95 nm, about 70 nm to about 95 nm, about 80 nm to about 95 nm, about 90 nm to about 95 nm, etc.). In accordance with one or more embodiments, the nanoparticles may be included in water-based compositions in different forms, including, for example, as discrete nanoparticles, encapsulated nano particles, agglomerated nanoparticles, or in a liquid suspension. In certain embodiments, the nanoparticles may comprise at least about 1% by weight of the water-based composition. In certain embodiments, the nanoparticles may comprise about 1% to about 90%, or about 5% to about 85%, or about 10% to about 80%, or about 15% to about 75%, or about 20% to about 70%, or about 25% to about 65%, or about 30% to about 60%, or about 35% to about 55%, or about 40% to about 50%, by weight of the water-based composition. The nanoparticles may be in the form of solid particles that are present in a dry form at some point either prior to or during introduction into the water composition. The nanoparticles may be suspended in a liquid medium prior to introduction in the water composition. The responsive nanoparticles may occupy narrow openings in various layers of stratified reservoirs having various levels of permeability and swell in these openings. Accordingly, the responsive nanoparticles may be suitable for use, for example, in oil recovery operations. For example, the responsive nanoparticles may be able to penetrate and seal spaces, including fractures, holes, cracks, spaces, or channels, in stratified reservoirs. FIG.1is a flow diagram that illustrates steps included in the method of enhancing the productivity of a subterranean wellbore production in a stratified fractured reservoir in accordance with one or more embodiments. The method may include introducing a mixture comprising water and a first set of nanoparticles to a first target zone of the subterranean wellbore in a stratified fractured reservoir, where the first set of nanoparticles has a size in a range of about 10 to about 100 nm, and where the first target zone is located in a high permeability layer of the subterranean wellbore; providing a first stimulation to the first set of nanoparticles to promote the reacting, where the first stimulation comprises acoustic waves having a frequency range of 1 kHz to about 10 kHz; introducing water to the first target zone; introducing a mixture comprising water and a second set of nanoparticles to a second target zone of the subterranean wellbore, where the second set of nanoparticles has a size in a range of about 1 to about 10 nm, and where the second target zone is located in a medium permeability layer of the subterranean wellbore; providing a second stimulation to the second set of nanoparticles to promote the reacting where the second stimulation comprises acoustic waves having a frequency range of 100 Hz to about 1 kHz; introducing water to the second target zone. The details of each step included in the method are described further below. More particularly, the steps of the method may include injecting a first small slug of responsive nanoparticles with sizes ranging from 10-100 nm, a pore volume of 0.1 cm3/g, and reactive to high frequency acoustic waves (1-10 kHz); allowing the first slug to reach the target region of high permeability; lowering an acoustic tool to the target region and generating acoustic waves (1-10 kHz) for a period of 1 month; swelling the injected nanoparticles of the first small slug and allowing them to occupy larger pore throats and fractures in the high permeability region; injecting water for a period of 3 months and pushing the injected—expanded slug of the swelled nanoparticles; injecting a second small slug of responsive nanoparticles with sizes ranging from 1-10 nm, a pore volume of 0.1 cm3/g, and reactive to low frequency acoustic waves (100 Hz-1 kHz); allowing the second slug to reach the targeted zone of medium permeability; lowering acoustic tool to the target depth of the medium permeability and generating acoustic waves (100 Hz-1 kHz) for a period of 1 month; swelling the nanoparticles of the second slug and allowing them to occupy larger pore throats and fractures of the zone of medium permeability; injecting water for 3 months for pushing the injected-expanded second slug of swelled nanoparticles; and injecting water in all three layers up to 1 pore volume, minimizing cross flow between the layers, providing uniform sweep efficiency and mobilizing remaining oil. The stratified fractured reservoir may include a porous or fractured rock formation beneath the earth surface, which may be dry land or ocean bottom. The well system may be for a hydrocarbon well, such as an oil well, a gas well, a gas condensate well, or a mixture of hydrocarbon-bearing fluids. The reservoir may include different layers of rock having varying characteristics, such as degrees of density, permeability, porosity, and fluid saturations. The formation may include a low-pressure formation (for example, a gas-depleted former hydrocarbon-bearing formation) and a water-bearing formation (for example, fresh water, brine, former waterflood). In the case of the well system being operated as a production well, the well system may facilitate the extraction of hydrocarbons (or production) from a hydrocarbon-bearing reservoir. In the case of the well system being operated as an injection well, the well system may facilitate the injection of substances, such as gas or water, into a hydrocarbon-bearing reservoir. The well system may include a subterranean wellbore including a bored hole that extends from the earth surface into the reservoir. The wellbore may be vertical, deviated, or horizontal. The wellbore may provide for the circulation of injection fluids to displace hydrocarbons within the reservoir. The injection fluid may be pumped into the reservoir forming a propagating flood fluid. Leakage of this flood fluid may occur when the fluid flows from permeable zones or fractures of the reservoir. In the present disclosure, permeable zones or fractures may refer to naturally occurring openings or fissures in the formation, fissures created by the drilling activities, or any other features of the formation in the vicinity of the wellbore which allow the migration of the flood fluid into the formation. The general location where the flood fluid is being lost into the formation may be referred to as a target zone. Leakage may occur at any location in the wellbore between the surface and the bottom of the wellbore and thus, any parts of the wellbore where leakage is occurring may be considered as a target zone. Nanoparticles Reactive to High Frequency Acoustic Waves In one or more embodiments, a method of enhancing the productivity of a subterranean wellbore production in a stratified fractured reservoir may include introducing nanoparticles to a target zone of a subterranean wellbore.FIG.2illustrates a well environment in a stratified fractured reservoir in which nanoparticles reactive to high frequency acoustic waves are introduced into an upper layer of the wellbore, where the upper layer is located in a high permeability zone. In one or more embodiments, nanoparticles reactive to high frequency acoustic waves may include any particles including metal particles, ceramic particles, crosslinkable polymers, polymerizable monomers, curable monomers and/or macromers, or gel forming compositions, or combinations thereof. More particularly, the nanoparticles responsive to high frequency acoustic waves may include, a cross-linking multi-functional monomer, a polymerization initiator, a cross-linking agent, a curing agent, a gel time moderating agent, a cure activator, or combinations thereof. Nanoparticles responsive to high frequency acoustic may also include metal particles such as iron, copper, and silver, among others. In particular embodiments, the metal particles may be encapsulated in a polymer or a surfactant and crosslinking agent. The nanoparticles reactive to high frequency acoustic waves may be excited by a stimulation, such as acoustic waves. In one or more embodiments, the nanoparticles responsive to high frequency acoustic waves may include other components, such as water, saline, salt, aqueous base, oil, organic solvent, synthetic fluid oil phase, aqueous solution, alcohol or polyol, cellulose, starch, alkalinity control agent, density control agent, density modifier, surfactant, emulsifier, dispersant, polymeric stabilizer, crosslinking agent, polyacrylamide, polymer or combination of polymers, antioxidant, heat stabilizer, foam control agent, solvent, diluent, plasticizer, filler or inorganic particle, pigment, dye, precipitating agent, rheology modifier, oil-wetting agent, set retarding additive, surfactant, gas, accelerator, weight reducing additive, heavy-weight additive, lost circulation material, filtration control additive, dispersant, salts, fiber, thixotropic additive, breaker, crosslinker, gas, rheology modifier, density control agent, curing accelerator, curing retarder, pH modifier, chelating agent, scale inhibitor, enzyme, resin, water control material, polymer, oxidizer, a marker, or a combination thereof. In some embodiments, the nanoparticles may be in an amount by weight of the composition injected in the wellbore ranging from a lower limit selected from any of 5 wt %, 10 wt % and 15 wt %, to an upper limit selected from any of 60 wt %, 70 wt %, 80 wt %, 90 wt % and 100 wt %, where any lower limit may be used in combination with any upper limit. In one or more embodiments, the shape of the nanoparticles responsive to high frequency acoustic waves may be spherical, cubic, cylindrical or any other regular or irregular shapes. In some embodiments, the nanoparticles may have a size ranging from about 10 nm to about 100 mm, such as a lower limit selected from any of about 10 nm, about 15 nm, about 20 nm, about 25 nm, about 30 nm, about 35 nm, about 40 nm, about 45 nm, about 50 nm, about 55 nm, about 60 nm, about 65 nm, about 70 nm, about 75 nm, about 80 nm, about 85 nm, about 90 nm about 95 nm, and about 100 nm to an upper limit selected from any of about 10 nm, about 15 nm, about 20 nm, about 25 nm, about 30 nm, about 35 nm, about 40 nm, about 45 nm, about 50 nm, about 55 nm, about 60 nm, about 65 nm, about 70 nm, about 75 nm, about 80 nm, about 85 nm, about 90 nm about 95 nm, and about 100 nm, where any lower limit may be used in combination with any upper limit. In one or more embodiments, the nanoparticles are responsive to acoustic waves having a frequency range of about 1 kHz to about 10 kHz, such as a lower limit selected from any of about 1 kHz, 2 kHz, 3 kHz, 4 kHz, 5 kHz, 6 kHz, 7 kHz, 8 kHz, 9 kHz, or 10 kHz to an upper limit selected from any of about 1 kHz, 2 kHz, 3 kHz, 4 kHz, 5 kHz, 6 kHz, 7 kHz, 8 kHz, 9 kHz, or 10 kHz. Nanoparticles Reactive to Low Frequency Acoustic Waves In one or more embodiments, a method of enhancing the productivity of a subterranean wellbore production in a stratified fractured reservoir may include introducing nanoparticles to a target zone of a subterranean wellbore.FIG.3illustrates a well environment in a stratified fractured reservoir in which nanoparticles reactive to low frequency acoustic waves are introduced into a middle layer of the wellbore, where the middle layer is located in a medium permeability zone. In one or more embodiments, nanoparticles reactive to low frequency acoustic waves may include any particles including metal particles, ceramic particles, crosslinkable polymers, polymerizable monomers, curable monomers and/or macromers, or gel forming compositions, or combinations thereof. More particularly, the nanoparticles may include, a cross-linking multi-functional monomer, a polymerization initiator, a cross-linking agent, a curing agent, a gel time moderating agent, a cure activator, or combinations thereof. Nanoparticles responsive to high frequency acoustic may also include metal particles such as iron, copper, and silver, among others. In particular embodiments, the metal particles may be encapsulated in a polymer or a surfactant and crosslinking agent. The nanoparticles reactive to low frequency acoustic waves may be excited by a stimulation, such as acoustic waves. In one or more embodiments, the nanoparticles may include other components, such as water, saline, salt, aqueous base, oil, organic solvent, synthetic fluid oil phase, aqueous solution, alcohol or polyol, cellulose, starch, alkalinity control agent, density control agent, density modifier, surfactant, emulsifier, dispersant, polymeric stabilizer, crosslinking agent, polyacrylamide, polymer or combination of polymers, antioxidant, heat stabilizer, foam control agent, solvent, diluent, plasticizer, filler or inorganic particle, pigment, dye, precipitating agent, rheology modifier, oil-wetting agent, set retarding additive, surfactant, gas, accelerator, weight reducing additive, heavy-weight additive, lost circulation material, filtration control additive, dispersant, salts, fiber, thixotropic additive, breaker, crosslinker, gas, rheology modifier, density control agent, curing accelerator, curing retarder, pH modifier, chelating agent, scale inhibitor, enzyme, resin, water control material, polymer, oxidizer, a marker, or a combination thereof. In some embodiments, the nanoparticles may be in an amount by weight of the composition injected in the wellbore ranging from a lower limit selected from any of 5 wt %, 10 wt % and 15 wt %, to an upper limit selected from any of 60 wt %, 70 wt %, 80 wt %, 90 wt % and 100 wt %, where any lower limit may be used in combination with any upper limit. In one or more embodiments, the shape of the nanoparticles may be spherical, cubic, cylindrical or any other regular or irregular shapes. In some embodiments, the nanoparticles may have a size ranging from about 1 nm to about 10 mm, such as a lower limit selected from any of about 1 nm, about 1.5 nm, about 2 nm, about 2.5 nm, about 3 nm, about 3.5 nm, about 4 nm, about 4.5 nm, about 5 nm, about 5.5 nm, about 6 nm, about 6.5 nm, about 7 nm, about 7.5 nm, about 8 nm, about 8.5 nm, about 9 nm about 9.5 nm, and about 10 nm to an upper limit selected from any of about 1 nm, about 1.5 nm, about 2 nm, about 2.5 nm, about 3 nm, about 3.5 nm, about 4 nm, about 4.5 nm, about 5 nm, about 5.5 nm, about 6 nm, about 6.5 nm, about 7 nm, about 7.5 nm, about 8 nm, about 8.5 nm, about 9 nm about 9.5 nm, and about 10 nm, where any lower limit may be used in combination with any upper limit. In one or more embodiments, the nanoparticles are responsive to acoustic waves having a frequency range of about 100 Hz to about 1 kHz, such as a lower limit selected from any of about 100 Hz, 200 Hz, 300 Hz, 400 Hz, 500 Hz, 600 Hz, 700 Hz, 800 Hz, 900 Hz, or 1 kHz to an upper limit selected from any of about 100 Hz, 200 Hz, 300 Hz, 400 Hz, 500 Hz, 600 Hz, 700 Hz, 800 Hz, 900 Hz, or 1 kHz. Introduction of Nanoparticles Reactive to High Frequency Acoustic Waves In some embodiments, the nanoparticles responsive to high frequency acoustic waves may be introduced to the wellbore, including a high permeability target zone, by incorporating the nanoparticles responsive to high frequency acoustic waves into a base fluid. A base fluid containing the nanoparticles responsive to high frequency acoustic waves may be any type of fluid that is suitable for dispersing the nanoparticles responsive to high frequency acoustic waves and carrying the nanoparticles to be introduced to the target zone of the wellbore. In some embodiments, the base fluid may contain additional fluids or additives. In some embodiments, the base fluid may be water. In one or more embodiments, the base fluid may contain nanoparticles responsive to high frequency acoustic waves in an amount ranging from about 0.1 wt % to 90 wt %. In some embodiments, the base fluid may contain nanoparticles responsive to high frequency acoustic waves in an amount ranging from a lower limit selected from any of 0.1 wt %, 0.5 wt %, 1 wt %, 2 wt %, 3 wt %, 4 wt %, and 5 wt % to an upper limit selected from any of 40 wt %, 50 wt %, 60 wt %, 70 wt %, 80 wt % and 90 wt %, where any lower limit may be used in combination with any upper limit. In other embodiments, the nanoparticles responsive to high frequency acoustic waves may be introduced to a stratified wellbore, including a target zone located in a high permeability zone of the wellbore, by incorporating the nanoparticles into a base fluid. The nanoparticles may thus be introduced to specific areas of the wellbore, such as the target zone, where the nanoparticles may come into contact with water, as described in detail below. In one or more embodiments, the amount of nanoparticles introduced to the wellbore may be adjusted according to the permeability of the target zone and other operational factors such as, but not limited to, the flow rate and viscosity of the injection fluid. Stimulation of Nanoparticles Reactive to High Frequency Acoustic Waves In one or more embodiments, the method of enhancing productivity of a subterranean wellbore may include providing stimulation to the nanoparticles. Stimulation may include, but is not limited to, a form of energy such as sound energy. In some embodiments, the stimulation may promote reaction, swelling or expansion of the nanoparticles.FIG.2illustrates a well environment in which the nanoparticles are introduced to the high permeability target zone of the wellbore, and a stimulation is being provided. In some embodiments, the stimulation may be provided as an energy form including acoustic waves. In one or more embodiments, the stimulation may be provided by a stimulation generator, such as an acoustic wave generator. Such generator may be incorporated into any suitable portion of the wellbore and may located within such portion via wireline placement for example. The stimulation may be provided continuously, or intermittently. The acoustic waves having a frequency range of about 1 kHz to about 10 kHz may be generated using a downhole acoustic wave generation tool. The tool may be placed permanently downhole or can be retrievable and used during the treatment operation. The acoustic waves may be applied to the high permeability target zone for a duration of about 1 week to 3 months, or about 2 weeks to 2 months, or for about 1 month and they may be adjusted and optimized based on the specific conditions of the enhanced productivity. The acoustic waves allow the nanoparticles introduced into the high permeability zone of the stratified wellbore to react and expand in size to about 10 to 100 microns. For example, in one or more embodiments, the nanoparticles may swell to a size having a lower limit of any of 10, 15, 20, 25, 30, 35, and 40 microns to an upper limit of any of 60, 70, 80, 85, 90, 95, and 100 microns, where any lower limit may be used in combination with any upper limit. The nanoparticle may swell and occupy larger pore throats and fractures in the high permeability region and result in the reduction the overall permeability of the target zone. Introduction of Nanoparticles Reactive to Low Frequency Acoustic Waves In some embodiments, the nanoparticles responsive to low frequency acoustic waves may be introduced to the wellbore, including a medium permeability target zone, by incorporating the nanoparticles responsive to low frequency acoustic waves into a base fluid. A base fluid containing the nanoparticles responsive to low frequency acoustic waves may be any type of fluid that is suitable for dispersing the nanoparticles responsive to low frequency acoustic waves and carrying the nanoparticles to be introduced to the target zone of the wellbore. In some embodiments, the base fluid may contain additional fluids or additives. In some embodiments, the base fluid may be water. In one or more embodiments, the base fluid may contain nanoparticles responsive to low frequency acoustic waves in an amount ranging from about 0.1 wt % to 90 wt %. In some embodiments, the base fluid may contain nanoparticles responsive to low frequency acoustic waves in an amount ranging from a lower limit selected from any of 0.1 wt %, 0.5 wt %, 1 wt %, 2 wt %, 3 wt %, 4 wt %, and 5 wt % to an upper limit selected from any of 40 wt %, 50 wt %, 60 wt %, 70 wt %, 80 wt % and 90 wt %, where any lower limit may be used in combination with any upper limit. In other embodiments, the nanoparticles responsive to low frequency acoustic waves may be introduced to a stratified wellbore, including a target zone located in a medium permeability zone of the wellbore, by incorporating the nanoparticles into a base fluid. The nanoparticles may thus be introduced to specific areas of the wellbore, such as the target zone, where the nanoparticles may come into contact with water, as described in detail below. In one or more embodiments, the amount of nanoparticles introduced to the wellbore may be adjusted according to the permeability of the target zone and other operational factors such as, but not limited to, the flow rate and viscosity of the injection fluid. Stimulation of Nanoparticles Reactive to Low Frequency Acoustic Waves In one or more embodiments, the method of enhancing productivity of a subterranean wellbore may include providing stimulation to the nanoparticles. Stimulation may include, but is not limited to, a form of energy such as sound energy. In some embodiments, the stimulation may promote reaction, swelling or expansion of the nanoparticles.FIG.3illustrates a well environment in which the nanoparticles are introduced to the medium permeability target zone of the wellbore, and a stimulation is being provided. In some embodiments, the stimulation may be provided as an energy form including acoustic waves. In one or more embodiments, the stimulation may be provided by a stimulation generator, such as an acoustic wave generator. Such generator may be incorporated into any suitable portion of the wellbore and may located within such portion via wireline placement for example. The stimulation may be provided continuously, or intermittently. The acoustic waves having a frequency range of about 100 Hz to about 1 kHz may be generated using a downhole acoustic wave generation tool. The tool may be placed permanently downhole or can be retrievable and used during the treatment operation. The acoustic waves may be applied to the medium permeability target zone for a duration of about 1 week to 3 months, or about 2 weeks to 2 months, or for about 1 month and they may be adjusted and optimized based on the specific conditions of the enhanced productivity. The acoustic waves allow the nanoparticles introduced into the medium permeability zone of the stratified wellbore to react and expand in size to about 10 to 100 microns. For example, in one or more embodiments, the nanoparticles may swell to a size having a lower limit of any of 10, 15, 20, 25, 30, 35, and 40 microns to an upper limit of any of 60, 70, 80, 85, 90, 95, and 100 microns, where any lower limit may be used in combination with any upper limit. The nanoparticle may swell and occupy larger pore throats and fractures in the medium permeability region and result in the reduction the overall permeability of the target zone. Introduction of Water In one or more embodiments, the method of enhancing productivity of a subterranean wellbore may include introducing water to the high permeability target zone of the stratified wellbore after the introduction and stimulation of the nanoparticles responsive to high frequency acoustic waves to push the injected expanded nanoparticles out from the high permeability zone. In one or more embodiments, the method of enhancing productivity of a subterranean wellbore may include introducing water to the medium permeability target zone of the stratified wellbore after the introduction and stimulation of the nanoparticles responsive to low frequency acoustic waves to push the injected expanded nanoparticles out from the medium permeability zone. In some embodiments, the water may be fresh water or saltwater, and may be obtained from natural sources or artificially produced. In some embodiments, the water may be introduced into the wellbore continuously or intermittently for a period of about 2 to about 5 months, or about 3 to about 5 months. In one or more embodiments, the water may have a pH of about 5.5 to about 7.5. In some embodiments, the method of enhancing the productivity of a subterranean wellbore may include, repeating one or more of the steps described above. In some embodiments, the repeating steps may include all steps included in the method of enhancing the productivity of the stratified subterranean wellbore. In other embodiments, selective steps of the method may be repeated. The number of repeated steps is not limited and may be repeated as many times as necessary until the productivity, injectivity, and sweep efficiency are enhanced. Each repeated process step may be the same as the previous iteration, or may be different, and may be adjust in accordance with a specific target for the productivity enhancement. In some embodiments, the stimulation generator may include an acoustic wave generator and may further include a control device such as a mobile control device, a sensor, a retrieval/deployment line, or a motor, capable of transferring to any location along the wellbore. The movement of the control device may be controlled mechanically by a retrieval/deployment line connected to the mitigation device and a line retrieval/deployment means such as a reel or a winch. In some embodiments, the control device may contain sensors which may include a camera, scanner, logging and scanning ring, hole caliper, or any other devices which may be used to measure or record various aspects of the downhole environment and the plugging process of the formation target zone. In some embodiments, the monitoring of the target zone may be conducted by the sensors included in the control device. The method according to one or more embodiments may be used in a stratified reservoir having an upper layer being a region of high permeability, a middle layer being a region of medium permeability and a lower region being a region of low permeability. The steps of the method may include injecting a first small slug (0.1 pore volume) of responsive nanoparticles (10-100 nm) reactive to high frequency acoustic wave (1-10 kHz); allowing the first slug to reach the target region of high permeability; lowering an acoustic tool to the target region and generating acoustic waves (1-10 kHz) for a period of 1 month; swelling the injected nanoparticles of the first small slug and allowing them to occupy larger pore throats and fractures in the high permeability region; injecting water for a period of 3 months and pushing the injected—expanded slug of the swelled nanoparticles; injecting a second small slug (0.1 pore volume) of responsive nanoparticles (1-10 nm), slug B, reactive to low frequency acoustic waves (100 Hz-1 kHz); allowing the second slug to reach the targeted zone of medium permeability; lowering acoustic tool to the target depth of the medium permeability and generating acoustic waves (100 Hz-1 kHz) for a period of 1 month; swelling the nanoparticles of the second slug and allowing them to occupy larger pore throats and fractures of the zone of medium permeability; injecting water for 3 months for pushing the injected-expanded second slug of swelled nanoparticles; and injecting water in all three layers up to 1 pore volume, minimizing cross flow between the layers, providing uniform sweep efficiency and mobilizing remaining oil. FIG.4illustrates a well environment in which the nanoparticles responsive to high frequency acoustic waves have sealed fractures in the high permeability zone of the stratified wellbore after their introduction and stimulation, and in which the nanoparticles responsive to low frequency acoustic waves have sealed fractures in the medium permeability zone of the stratified wellbore after their introduction and stimulation, thus reducing the permeability contrast between the zones of the stratified wellbore and thus enhancing the productivity. Injection of water in all three layers of the stratified wellbore by up to 1 pore volume may result in minimizing crossflow between layers, providing uniform sweep efficiency and effectively mobilizing the remaining oil for higher oil recovery. The method of enhancing the productivity of a subterranean wellbore described in the previous paragraphs may be applied to injection well, a production well, a deep well, a shallow single well, a shallow multilateral well, a vertical well, or a horizontal well. Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S.C. § 112(f) for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function. | 32,312 |
11859485 | DETAILED DESCRIPTION Certain aspects and examples of the present disclosure relate to a trip map for adjusting a tripping operation with respect to a wellbore. The tripping operation can be performed to, for example, replace a worn-down drill bit at a downhole end of the drill string. The trip map can be generated for an interval of the wellbore during the tripping operation. The trip map can be a visual representation of the parameters, the overall condition, and the status of the wellbore during the tripping operation, and can be provided on a user interface and otherwise used to adjust the tripping operation. In some examples, tripping operation set points for the interval of the wellbore can be determined based on the trip map. Moreover, the trip map for the interval of the wellbore can indicate that the wellbore is unstable, for example, due to excess pressure from the force of replacing a drill string. The tripping operation can be adjusted based on the trip map to reduce pressure and improve the stability of the wellbore. Examples of parameters can include swab influx, swab pressure, runnability index, equivalent circulating density, equivalent mud weight, optimum speed, static drag, and pore pressure. The overall condition can be a measurement of the condition of the tripping operation with respect to the wellbore. The overall condition can be determined by combining parameter values to generate an overall condition value. The status of the tripping operation can be an indication of the stability of the wellbore during the tripping operation. The status can be determined by comparing the parameter values to measured values from theoretical data or by comparing the overall condition value to a measured overall condition value. The stability, conditions, or additional features of the wellbore can change significantly over a length of the wellbore during the tripping operation, which can make it difficult to determine the parameters and the overall condition of the tripping operation with respect to the wellbore. Additionally, the current techniques that can provide tripping operation set points, operational parameters, or control parameters for the tripping operation are inefficient and time consuming. Thus, a strategy is needed for determining tripping operation set points, operational parameters, control parameters, or a combination thereof faster to maintain optimal conditions or stability in the wellbore during the tripping operation. The trip map can provide the parameters and the overall condition of the tripping operation in an intuitive and efficient manner. The trip map can be used to improve the efficiency of the tripping operation by enabling quick decisions regarding operational parameters, control parameters, tripping operation set points, or a combination thereof. The increase in efficiency of the tripping operation due to the trip map can be analyzed with ultimate cost and outcome functions. The trip map can provide parameter conditions and overall conditions of the tripping operation by bracketing various parameters under a corresponding unit condition. The parameter conditions, overall conditions, or a combination thereof can be used to determine tripping operation set points during the tripping operation in the wellbore. For example, in an autonomous drilling system, the tripping operation setpoints, operational parameters, and control parameters for the tripping operation can be determined using a decision-making control loop that includes the trip map. The decision-making control loop that includes the trip map can provide effective solutions for the autonomous drilling system or any other well system. In additional examples, the efficiency of the tripping operation can be estimated based off a comparison of a set of current operational parameters for the tripping operation and the operational parameters determined using the trip map. The trip map can also facilitate better forward prediction of the operational efficiency of future tripping operations. The trip map can further enable analysis of the stability of the wellbore. For example, the trip map can provide a region in which the wellbore is subject to excess pressure from tripping operation. The trip map can be displayed as a two-dimensional trip map or a three-dimensional trip map. The trip map can include various control parameters such as runnability, trip speed, equivalent circulating density, kick, loss indicators, etc. The various control parameters can be mapped on the trip map, compared against theoretical models, and made on a unit line on the trip map. Additional parameters can include pick up or slack off drag values. The overall condition can be a combination of the various control parameters or additional parameters. The depth of the wellbore versus the overall condition of the tripping operation and individual control parameters, operational parameters, or other suitable parameters can be monitored throughout the tripping operation to analyze trends of the tripping operation with respect to the wellbore. The trip map can include additional limits that can be calculated for a sub-interval of the wellbore during the tripping operation. Optimal limit values can also be calculated during the tripping operation based on wellbore pressure or additional wellbore conditions. The sub-interval can be selected to be small enough that the calculations in the sub-interval can be assumed to be constant over the sub-interval. For example, the sub-interval selected can be 1 foot. For the sub-interval, it can be assumed that the wellbore pressure changes continuously during the tripping operation and that the amount of change depends on uncontrolled or uncertain parameters. Uncontrolled or uncertain parameters can include formation, anisotropy, dip, etc. Additionally, the limits may be calculated continuously during the tripping operation due to changes in the formation and depth of the wellbore, the friction factor, rock strength, the length of drill pipe, or additional parameter changes. A drilling interval may also be established or adjusted based on the limits calculated. The limits calculated can include torsional instability, lateral instability, rate of penetration (ROP) coupled bit wear, hole cleaning, mechanical specific energy, motor stall weight, motor stall speed, or other suitable limits. An optimized, stable region of the wellbore can be calculated bounded with the limits. The optimization of regions of the wellbore using the limits can be used to obtain operational parameters to improve the efficiency of the tripping operation or to place a well efficiently. Illustrative examples are given to introduce the reader to the general subject matter discussed herein and are not intended to limit the scope of the disclosed concepts. The following sections describe various additional features and examples with reference to the drawings in which like numerals indicate like elements, and directional descriptions are used to describe the illustrative aspects, but, like the illustrative aspects, should not be used to limit the present disclosure. FIG.1is a schematic of a well system100that can facilitate a tripping operation according to one example of the present disclosure. As illustrated, the well system100includes a wellbore108formed in a subterranean formation104. The subterranean formation104can include sandstone, limestone, or additional rock formations. As illustrated, the wellbore108is at least partially drilled and completed. The wellbore108can include a casing string112that can be cemented within the wellbore108and can provide a conduit for produced formation fluids, such as oil or gas, to travel from downhole in the wellbore108to the well surface102. Additionally, the wellbore108can include a drill string114that can include drill pipe, heavy weight drill pipe, drill collars and additional components such as stabilizers and drilling jars. The drill string114can be used to suspend a drill bit118, which can drill through various layers of the subterranean formation104. The drill string114can further transmit a rotary motion to the drill bit118or provide a flow path to circulate drilling fluids. In some examples, the well system100can facilitate a tripping operation. During the tripping operation, the drill string114can be removed or replaced in an open hole portion116(or other suitable portion) of the wellbore108. Removing the drill string114can be referred to as tripping out and replacing the drill string114can be referred to as tripping in. A tripping-out operation can include pulling a first portion of the drill string114out of the wellbore108, disconnecting the first portion of the drill string114, removing the first portion of the drill string114via a derrick, and storing the first portion of the drill string114on a pipe storage rack. The tripping out tripping operation can be repeated until a certain amount of the drill string114is removed from the wellbore108. In an example, the drill string114can be disconnected at every third joint or every 30 meters (98.42 feet) as the drill string114is pulled out of the wellbore108. A tripping-in operation can include reconnecting the first portion of the drill string114, guiding the first portion of the drill string114downhole in the wellbore108, and repeating with subsequent portions of the drill string114until the certain amount of the drill string114is replaced in the wellbore108. The tripping operation may be performed when a drill bit118has become worn-down, to replace downhole tools in the wellbore108, or to replace damaged drill string114. The wellbore108can endure reduced pressure during the tripping out tripping operation and increased pressure during the tripping-in operation. Other suitable examples of a tripping operation involving the well system100are possible. Parameters relating to the wellbore108or relating to the tripping operation can be determined and monitored. The parameters of the tripping operation can be determined based on data collected by a downhole tool117, such as a measurement-while-drilling (MWD) tool or a logging-while-drilling (LWD) tool, positioned downhole in the wellbore108. The data collected by the downhole tool117can be received by a computing device130. In an example, the downhole tool117collects data for a predetermined interval of the wellbore108during the tripping operation. The predetermined interval can be set or adjusted by an operator or autonomously by the computing device130. The computing device130may access one or more micro-services, engineering models, or the like to output the parameters. Parameters of the tripping operation can include swab influx, swab pressure, runnability index, equivalent circulating density, equivalent mud weight, optimum speed, static drag, pore pressure, or other suitable parameters. Swab influx can be an influx of fluid into the wellbore108due to the removal or replacement of the drill string114. Swab pressure can be a change in pressure in the wellbore108due to the removal or replacement of the drill string114. Runnability index can be a measure of the performance or efficiency of the tripping operation. Equivalent circulating density can be a density exerted on the wellbore108by a circulating fluid in the wellbore108. Equivalent mud weight can be a mud weight needed to balance a pressure imposed on the wellbore108by the circulating fluid. The optimum speed can refer to the speed the drill string114is moved during an interval or throughout the tripping operation while maintaining the stability of the wellbore108. Pore pressure can be a pressure of fluids within the pores of the subterranean formation104. The computing device130can generate a trip map that includes the parameters listed above, additional parameters relating to the wellbore108, additional parameters relating to the tripping operation, or a combination thereof. The tripping operation can be adjusted or controlled based on the trip map. For example, swab pressure for an interval of the wellbore108can be determined based on data collected by the downhole tool117. The computing device130can map the swab pressure on the trip map in an area that correlates to a status of the swab pressure. The status of the swab pressure can be determined by comparing the swab pressure to a measured swab pressure based on theoretical data. In an example, the status of swab pressure can be insufficient, which can indicate that the swab pressure is too high. In response, the speed of the tripping operation can be decreased to improve swab pressure. The tripping operation can also stop, restart, sped up, change direction, or otherwise be altered based on the trip map. The computing device130can display the trip map on a user interface for an operator to analyze and adjust the tripping operation or the computing device130can provide the trip map as an input for autonomously controlling the tripping operation. FIG.2is a block diagram of a computing device130for adjusting a tripping operation in a wellbore108using a trip map215according to one example of the present disclosure. The components shown inFIG.2, such as a processor204, a memory207, a power source220, an input/output232, and the like may be integrated into a single structure such as within a single housing of a computing device130. Alternatively, the components shown inFIG.2can be distributed from one another and in electrical communication with each other. The computing device130can include the processor204, the memory207, and a bus206. The processor204can execute one or more operations for determining optimal tripping operation parameters using one or more optimization models subject to one or more constraints. The processor204can execute instructions210stored in the memory207to perform the operations. The processor204can include one processing device or multiple processing devices or cores. Non-limiting examples of the processor204include a Field-Programmable Gate Array (“FPGA”), an application-specific integrated circuit (“ASIC”), a microprocessor, etc. The processor204can be communicatively coupled to the memory207via the bus206. The non-volatile memory207may include any type of memory device that retains stored information when powered off. Non-limiting examples of the memory207may include EEPROM, flash memory, or any other type of non-volatile memory. In some examples, at least part of the memory207can include a medium from which the processor204can read instructions210. A computer-readable medium can include electronic, optical, magnetic, or other storage devices capable of providing the processor204with computer-readable instructions or other program code. Nonlimiting examples of a computer-readable medium include (but are not limited to) magnetic disk(s), memory chip(s), ROM, RAM, an ASIC, a configured processor, optical storage, or any other medium from which a computer processor can read instructions210. The instructions210can include processor-specific instructions generated by a compiler or an interpreter from code written in any suitable computer-programming language, including, for example, C, C++, C#, Perl, Java, Python, etc. In some examples, the memory207can be a non-transitory computer readable medium and can include computer program instructions210. For example, the computer program instructions210can be executed by the processor204for causing the processor204to perform various operations. For example, the processor204can receive input data211from a downhole tool117in the wellbore108and can determine parameters213for the tripping operation with respect to the wellbore108based on the input data211. The input data211can be collected and the parameters213can be determined for a predetermined interval212of the wellbore108. The parameters213can be combined to determine an overall condition214of the tripping operation. The parameters213can be used to determine the overall condition214or a subset of the parameters213can be used to determine the overall condition214. The overall condition214can be a measurement of the condition of the tripping operation with respect to the wellbore108. Values of the parameters213can be added together or otherwise combined to generate an overall condition value. In some examples, the overall condition value can be compared to a measured overall condition value, based on measured values of the parameters213from theoretical data, to determine a status of the overall condition214of the tripping operation. The status of the overall condition214of the tripping operation can be related to the stability of the wellbore108. A status can also be determined for the parameters213by comparing a parameter213to a measured parameter based on theoretical data. In some examples, the status of the parameters213or the overall condition214of the tripping operation can be optimal, sufficient, or insufficient. Additionally, the processor204can generate a trip map215that can include the parameters213, the overall condition214, and corresponding statuses of the parameters213and the overall condition214for the tripping operation. A new trip map or an updated trip map can be generated for every predetermined interval212of the wellbore108. The computing device130can additionally include an input/output232. The input/output232can connect to a keyboard, a pointing device, a display, other computer input/output devices or any combination thereof. An operator or other suitable user may provide input using the input/output232. Data relating to the wellbore108, the tripping operation, the trip map215, or a combination thereof can be displayed to an operator or other suitable user related to the tripping operation through a display that is connected to or is part of the input/output232. The displayed values can be observed by the operator, a supervisor, or other suitable user related to the tripping operation, who can adjust the tripping operation based on the displayed values. Alternatively, the computing device130can, instead of displaying the values, automatically control or adjust the tripping operation based on the trip map215. The computing device130can control the tripping operation automatically by inputting one or more tripping operation set points, control parameters, operational parameters, or additional parameters determined using the trip map to an autonomous system performing the tripping operation. FIG.3is a flowchart of a process300for adjusting a tripping operation in a wellbore108using a trip map215according to one example of the present disclosure. The tripping operation can be adjusted by an operator based on the trip map215or the tripping operation can be adjusted automatically based on the trip map215. The tripping operation can involve removing or replacing a drill string114or other suitable components in the wellbore108. At block302, computing device130receives input data211for a predetermined interval212of the wellbore108from a downhole tool117and uses the input data211to determine parameters213related to the tripping operation. The input data211can be data relating to the wellbore108, the drill string114, the subterranean formation104, geothermal context in the subterranean formation104, or any other suitable data that can affect the tripping operation. The downhole tool117can be a measurement-while-drilling (MWD), logging-while-drilling (LWD) tool, distributed acoustic sensor, or other suitable tool for collecting data during the tripping operation. The computing device130may input the input data211into a micro-service, an engineering model, or the like to generate parameters213. The micro-service can be a small independent service that serves a single function, such as returning a parameter213based on the input data211. The engineering model can be a technique for analyzing, determining, validating, or a combination thereof the parameters213based on the input data211. The parameters213of the tripping operation can change over the length of the wellbore108, thus input data211can be collected for the predetermined interval212. The predetermined interval212of the wellbore108can be chosen or adjusted by an operator or automatically by the computing device130. Additionally, a tripping operation can be performed in intervals as a portion of the drill string114or another suitable component is removed or replaced in the wellbore108. As a result, the predetermined interval212of the wellbore108may relate to a length of the portion of the drill string114. The parameters213can include tripping operation set point parameters for planning the tripping operation, control parameters for controlling the tripping operation, and wellbore parameters for monitoring the wellbore conditions during the tripping operation. Examples of the tripping operation set point parameters can include a speed of the tripping operation, a length of the portion of the drill string removed or replaced in an interval of the tripping operation, or any other suitable parameters for planning the tripping operation. Examples of the control parameters can include runnability index, equivalent circulating density, equivalent mud weight, optimum speed, static drag, or additional parameters related to controlling the tripping operation. Examples of the wellbore parameters can include inclination, pore pressure, rock strength, swab influx, swab pressure, or other suitable parameters related to monitoring wellbore conditions. At block304, the computing device130determines an overall condition214for the predetermined interval212of the wellbore108during the tripping operation based on the parameters213. The overall condition214can be an estimation of the condition of the tripping operation with respect to the wellbore108and can be used to determine the stability of the wellbore108. The overall condition214can be determined by adding values of the parameters213together or otherwise combining the parameters213to provide the overall condition214. An estimated value can also be determined for the overall condition214based on theoretical data, historical data, or a theoretical model. At block306, the computing device130determines at least one status for each of the parameters213and for the overall condition214based on a difference between at least one value for the parameters213or the overall condition214and a corresponding optimized value. The at least one value for the parameters213or the overall condition214can be based on input data211and can be calculated by a microservice, engineering model, or the like. The corresponding optimized value can be based on historical data, theoretical data, a theoretical model, or other suitable techniques or data for estimating the parameters213or the overall condition214. The corresponding optimized value may also be output from a microservice, engineering model, or the like and can represent the optimal value for the parameters213or the overall condition214. In some examples, the at least one status can include three statuses that can indicate the parameters213or overall condition214are optimal, sufficient, or insufficient. The status determined for a parameter value close to a corresponding estimated value can be optimal. The status determined for a parameter with a small difference between a value for the parameter and a corresponding estimated value can be sufficient. The status determined for a parameter with a large difference between a value for the parameter and a corresponding estimated value can be insufficient. At block308, the computing device130generates a trip map215based on the parameters213and the overall condition214for the predetermined interval212of the wellbore108. The trip map215can be generated by computing device130for display on a user interface or the trip map can be generated by computing device130and input into an autonomous system controlling the tripping operation. The size, shape, colors, or other characteristics of the trip map can be adjusted by a user when generating the trip map215. The trip map215can be a visual representation of the plurality of parameters and the overall condition. The trip map can include a background shape that can include the parameters213and the overall condition214positioned angularly around the background shape. The background shape can be two-dimensional or three-dimensional. In some examples the background shape can include a circle or a cylinder, however additional background shapes may be used for the trip map215. The trip map215may further include a polygon that can be positioned on the background shape. The polygon can include corners that correspond to the overall condition214, the parameters213, or a combination thereof. Additionally, the corners can be positioned on the trip map215at different radial positions based on the at least one status for the parameters213or overall condition214. For example, the trip map215can include three status regions and the corners of the polygon corresponding to the parameters213and the overall condition214can be mapped in the status region corresponding to the previously determined at least one status. In some examples, the tripping operation may be adjusted to improve the parameters213or the overall condition214when the corner for a parameter is positioned in an area on the trip map indicating its status is insufficient (e.g., unsafe, suboptimal, or the like). At block310, the computing device130outputs the trip map215that can be used to adjust the tripping operation. The status of the overall condition214or the status of the parameters213can be used to determine an adjustment to the tripping operation. In some examples, the status of the overall condition214or the status of the parameters213for a predetermined interval212in the wellbore108can be sufficient or insufficient on the generated trip map215. In response, the tripping operation can be slowed down, sped up, temporarily stopped, or otherwise altered to improve the overall condition214or the parameters213. Additionally, the overall condition214, the parameters213, or a combination thereof can be optimized for the tripping operation using the trip map215. The optimized parameters213or optimized overall condition214can be used to predict tripping operation set point parameters or control parameters in future tripping operations. The trip map215can be used as an input for autonomously adjusting the tripping operation or the trip map215can be analyzed by an operator or other user for adjusting the tripping operation. FIG.4is an example of a two-dimensional trip map400according to one example of the present disclosure. The two-dimensional trip map400can be generated for the predetermined interval212, or any subset thereof, along the length of a wellbore108to continuously monitor the tripping operation and the stability of the wellbore108. The two-dimensional trip map400can be generally shaped as a circle split into status regions404a-c, which can indicate a status of a parameter402a-gor the status of an overall condition408for the predetermined interval212of the wellbore108. Other suitable shapes (e.g., other than a circle) can be depicted by the two-dimensional trip map400. An operator, crew member, or other user can adjust the colors of status regions402a-c, the size of the status regions402a-c, the size of the circle that includes the status regions402a-c, or a combination thereof. The two-dimensional trip map400can include parameters402a-gthat can be mapped, compared to theoretical models, and placed on a unit line406on the two-dimensional trip map400. The parameters402a-gcan be determined in real-time during the tripping operation by collecting data from the wellbore108and inputting the data into micro-services. The micro-services can be services built as part of an application organized into micro-services. The micro-services can be for specific business capabilities and can perform a single function such as determining one or more of the parameters402a-g. The parameters402a-gcan include swab influx, swab pressure, runnability index, equivalent circulating density, equivalent mud weight, optimum speed, static drag, pore pressure, additional parameters, or a combination thereof. The two-dimensional trip map400can further include a polygon410that is created by connecting points corresponding to parameters402a-g. Thus, the corners of the polygon410correspond to the parameters402a-gand the number of sides of the polygon410depends on the number of parameters402a-g. The placement of the corners of the polygon410can be determined by the values of parameters402a-gwith respect to their optimal values. In some examples, the value for a parameter402a-gcan be divided by an optimal value for the parameter. If a result of diving the parameter402a-gby the optimal value is equal to or less than one, the corner of the polygon410acan be in status region404a, indicating the value is within an optimal value range. The status region404acan include the center of the two-dimensional trip map400. If the result is higher than one, the corner of the polygon410can be placed in the status region404b. If the result is significantly higher than one, the corner of the polygon410can be in the status region404c. The status region404bcan indicate that the parameter value is sufficient and the status region404ccan indicate the parameter value is insufficient. Thus, the more undesirable the values for parameters402a-gare, the further out on the two-dimensional trip map400corresponding corners of the polygon may be placed. Additionally, the parameters402a-gcan be combined to determine an overall condition408of the tripping operation. The overall condition408can be placed on the two-dimensional trip map400in a status region404a-c. As illustrated, the overall condition408in the two-dimensional trip map400is in the sufficient region. In some examples, the corner of the polygon410corresponding to the overall condition408, can be determined by adding the parameter values together and dividing by an estimated value for the overall condition408. The estimated value for the overall condition408can be based on theoretical data for the parameters402a-g. The trip map, including the shape of the polygon410, the status regions404a-c, parameters402a-gpointed to by unit lines406, and the overall condition408, can be used for quick decision-making during the tripping operation. As illustrated, swab pressure402b, optimum speed402e, and overall condition408are in the status region404b, indicating that the corresponding values are above the optimal values and outside of the optimal value range. The tripping operation can be adjusted based on swab pressure402band optimum speed402eto improve the overall condition408. For example, the speed of the tripping operation may be decreased to bring the optimum speed402eand the swab pressure402bto the optimal region402a. The two-dimensional trip map400for the next predetermined interval212of the tripping operation can indicate if the speed was decreased enough, not enough, or too much and a subsequent adjustment can be made. The two-dimensional trip map400can be used as input for adjusting the tripping operation autonomously or an operator can determine the adjustment by viewing the two-dimensional trip map400on a user interface. FIG.5is an example of a three-dimensional trip map500according to one example of the present disclosure. The three-dimensional trip map500can be a cylinder or any other suitable, three-dimensional shape and can be generated for each predetermined interval212, or any subset thereof, along the length of a wellbore108to monitor the parameters502a-gand overall condition508. The cylindrical shape of the three-dimensional trip map500can be a scaled version of the predetermined interval212of the wellbore108. An operator of the tripping operation or another user can adjust characteristics of the three-dimensional trip map500. For example, the colors of status regions502a-c, the size of the status regions502a-c, or the dimensions of the three-dimensional trip map500(e.g., the diameter of ends512aand512cor the length of the cylinder) can be altered. The predetermined interval212can be chosen such that parameters502a-gand the overall condition508can be considered constant over the predetermined interval212. The parameters502a-gthat can be mapped and compared to theoretical models and placed on a unit line506on the three-dimensional trip map500. The parameters502a-gcan be determined in-real time during the tripping operation by collecting data from the wellbore108via a downhole tool117and inputting the data into engineering models or micro-services. The parameters502a-gcan include swab influx, swab pressure, runnability index, equivalent circulating density, equivalent mud weight, optimum speed, static drag, or pore pressure. The three-dimensional trip map500can also include ends512aand512c. As illustrated, circle514shows the outer part of ends512aand512b, while ends512aand512bshow the inner part of the three-dimensional trip map500. The three-dimensional trip map500can be split into status regions504a-c. The status region504acan be a small cylindrical region in the center of the three-dimensional trip map500and can represent the optimal area for parameters502a-g. The status regions504band504ccan be tubular regions that make up the remainder of the three-dimensional trip map500and can represent sufficient and insufficient areas respectively for parameters502a-g. The three-dimensional trip map500can further include a polygon510. The polygon510can be generated by connecting points corresponding to parameters502a-g. The corners of the polygon510can be measurements of the parameters502a-gwith respect to their optimal values. In some examples, the values for parameters502a-goutputted by the micro-service can be divided by optimal values. If the result is equal to or less than one, the point corresponding to the parameter can be in status region504a. If the result is higher than one, the corner of the polygon510can be placed in status regions504bor504c. A parameter502a-gor overall condition508in status region504cmay indicate that the wellbore108is unstable. Additionally, the parameters502a-gcan be combined to determine the overall condition508of the tripping operation. In some examples, the overall condition508can be determined by adding the parameter values together and dividing by an estimated value for the overall condition508. If the result is equal to or less than one, the overall condition508can be in status region504a, otherwise the overall condition508can be in status region504bor status region504c. The estimated value for the overall condition508can be based on theoretical data. As illustrated, the overall condition508in the three-dimensional trip map500is in the status region504b, suggesting that the overall condition508for the current predetermined interval212of the wellbore108is not optimized. As illustrated, the swab pressure502band the optimum speed502eare in the status region404b, indicating that both values are outside the optimal value range. The swab pressure502band the optimum speed502ecan be the reason the overall condition508is not optimized. The tripping operation can be adjusted based on the swab pressure502band the optimum speed502eto optimize the overall condition508. For example, the speed of the tripping operation may be decreased to decrease the optimum speed502eand swab pressure502b. The three-dimensional trip map500for the subsequent predetermined interval212of the tripping operation can depict if the speed was decreased enough, not enough, or too much and a subsequent adjustment can be made. The three-dimensional trip map500can be used as input for adjusting the tripping operation autonomously or an operator can determine the adjustment by viewing the three-dimensional trip map500on a user interface. FIG.6is an example of an overall condition plot600according to one example of the present disclosure. The overall condition plot600can include a first trendline602representing one or more overall conditions and a limit line604. The one or more overall conditions can be plotted at a depth614corresponding to the one or more predetermined intervals212of a wellbore108. Thus, the first trendline602can show the general course of the overall conditions of the tripping operation over the corresponding predetermined intervals212along the length of the wellbore108. The limit line604can be determined using one or more calculated limiting values. The calculated limiting values can include torsional instability, lateral instability, ROP coupled bit wear, hole cleaning, mechanical specific energy, hydro mechanical specific energy, motor stall weight, or motor stall speed. The optimal overall condition of the tripping operation for a stable wellbore can be bounded by the limiting values. The areas of the overall condition plot600where an overall condition line (e.g., the first trendline602) crosses over the limit line604can include an intuitive visual representation of the stability of the wellbore108. The overall condition plot600can be overlaid with additional information to provide a comprehensive view of the tripping operation. In some examples, a trip map606for an overall condition can be overlaid on the overall condition plot600. As illustrated, the trip map606for a portion of the first trendline602that crosses the limit line604is overlaid on the overall condition plot600. The depth614corresponding to the portion of the first trendline602can be used to locate an unstable region of the wellbore108. The trip map606can provide information on the parameters that relate to the unstable region of the wellbore108. Additionally, the overall condition plot600can include a second trendline608that represents lithology conditions at corresponding depths614in the wellbore108and geo-mechanical maps610a-c. The second trendline608and the geo-mechanical maps610a-ccan provide information on the subterranean formation104and can be used to find correlations between the stability of the wellbore108during the tripping operation and characteristics of the subterranean formation104. The geo-mechanical maps610a-ccan include a legend612to clarify which areas of the geo-mechanical maps610a-crepresent stable wellbore conditions and which areas represent unstable wellbore conditions. The geo-mechanical maps610a-ccan also be placed on the overall condition plot600at the depth614in the wellbore108the geo-mechanical map610a-cdepicts. In some examples, the overall condition plot600can be used to quickly determine an adjustment to the tripping operation. The overall condition plot600can be displayed on a user interface for an operator of the tripping operation, or the overall condition plot600can be used as input to autonomously control the tripping operation. Additionally, the overall condition plot600can be used to analyze tripping operation conditions, wellbore conditions, wellbore stability, or a combination thereof after the tripping operation to improve subsequent tripping operations. FIG.7is an example of a user interface700for providing the trip map and other suitable features according to one example of the present disclosure. As illustrated, the user interface700includes a two-dimensional trip map702, an operational status legend704, and an overall condition plot706, however the user interface700may include other suitable plots or sections related to the tripping operation. The two-dimensional trip map702may include parameters and an overall condition. The two-dimensional trip map702can further include kick, loss, and back-reaming conditions. The overall condition plot706may include the overall conditions for one or more intervals of a wellbore108plotted at corresponding depths. As illustrated, a trendline can be created on overall condition plot706by connecting overall conditions for predetermined intervals along the length of the wellbore108. The computing device130may generate and output the trip map702for providing via the user interface700. In some examples, a new trip map can be generated and displayed on the user interface700for the predetermined interval212of the wellbore108. Additionally, the overall condition plot706can be updated with the overall condition from the new trip map. In some examples, the user interface700may display the trip map702from a predetermined interval212of the wellbore108the drill string114has not entered to check the stability of the wellbore108prior to performing the tripping operation. In other examples, the trip map702can show a predetermined interval of the wellbore108during the tripping operation to check the stability of the wellbore108during or after the tripping operation. Moreover, the tripping operation can be adjusted or controlled autonomously based on two-dimensional the trip map702, the overall condition plot706, other suitable displays, or a combination thereof on user interface700. In some aspects, systems, methods, and non-transitory computer-readable mediums for a trip map for adjusting a tripping operation in a wellbore are provided according to one or more of the following examples: As used below, any reference to a series of examples is to be understood as a reference to each of those examples disjunctively (e.g., “Examples 1-4” is to be understood as “Examples 1, 2, 3, or 4”). Example 1 is a system comprising: a processor; and a non-transitory computer-readable medium that includes instructions executable by the processor for causing the processor to perform operations comprising: receiving input data for a predetermined interval of a wellbore from a downhole tool deployable in the wellbore, the input data usable to determine a plurality of parameters relating to a tripping operation with respect to the wellbore; determining an overall condition for the predetermined interval of the wellbore during the tripping operation based on the plurality of parameters; determining at least one status for each parameter of the plurality of parameters and for the overall condition based on a difference between at least one value for the plurality of parameters or the overall condition and a corresponding optimized value; generating a trip map based on the plurality of parameters and the overall condition for the predetermined interval of the wellbore, the trip map being a visual representation of the plurality of parameters and the overall condition, the trip map comprising: a background shape including the plurality of parameters and the overall condition positioned angularly around the background shape; a polygon positioned on the background shape, the polygon including a plurality of corners, each corner of the plurality of corners corresponding to the overall condition or to different parameters of the plurality of parameters, each corner positioned at different radial positions of the background shape based on the at least one status; and outputting, by a user interface, the trip map that is usable to adjust the tripping operation. Example 2 is the system of example 1, wherein the plurality of parameters includes tripping operation set point parameters for planning the tripping operation, control parameters for controlling the tripping operation, and wellbore parameters for monitoring wellbore conditions during the tripping operation. Example 3 is the system of example 1, wherein the operation of outputting the trip map further comprises: generating visual indicators for the plurality of parameters in the trip map, the visual indicators connecting the plurality of corners of the polygon to the plurality of parameters; determining optimized values for the plurality of parameters based on theoretical data; determining measured values for the plurality of parameters based on the input data; determining the at least one status of the plurality of parameters based on differences between the optimized values and the measured values; generating at least one circular region on the trip map corresponding to the at least one status of the plurality of parameters; and providing, via the user interface, the trip map with the polygon and the visual indicators for the plurality of parameters in the at least one circular region for adjusting the tripping operation. Example 4 is the system of example 1, further comprising outputting an overall condition plot by: determining the overall condition for the predetermined interval by combining values of the plurality of parameters to generate a value for the overall condition; plotting the overall condition at a depth corresponding to the predetermined interval; generating a trendline by connecting a plurality of overall conditions with the trendline over a certain depth; and providing, via the user interface, the trendline. Example 5 is the system of example 1, wherein the operation of determining the overall condition comprises: determining an optimized value for the overall condition based on theoretical data; determining a measured value for the overall condition based on the plurality of parameters; and comparing the optimized value of the overall condition to the measured value of the overall condition. Example 6 is the system of example 1, further comprising the operation of adjusting the tripping operation by adjusting at least one aspect of the tripping operation, the at least one aspect including a speed of the tripping operation, a direction of the tripping operation, or stopping or resuming the tripping operation. Example 7 is the system of example 1, wherein the plurality of parameters includes swab influx, swab pressure, runnability index, equivalent circulating density, equivalent mud weight, optimum speed, static drag, and pore pressure. Example 8 is the system of example 1, further comprising adjusting the tripping operation autonomously by: receiving the trip map or an overall condition plot; determining an adjustment to the tripping operation based on the trip map or the overall condition plot; and adjusting the tripping operation based on the adjustment. Example 9 is the system of example 1, wherein the trip map is a three-dimensional trip map, wherein the three-dimensional trip map is a cylindrical visual representation of the plurality of parameters and the overall condition, and wherein the three-dimensional trip map includes a length of the predetermined interval. Example 10 is a method comprising: receiving, by a processing device, input data for a predetermined interval of a wellbore from a downhole tool deployable in the wellbore, the input data usable to determine a plurality of parameters relating to a tripping operation with respect to the wellbore; determining, by the processing device, an overall condition for the predetermined interval of the wellbore during the tripping operation based on the plurality of parameters; determining, by the processing device, at least one status for each parameter of the plurality of parameters and for the overall condition based on a difference between at least one value for the plurality of parameters or the overall condition and a corresponding optimized value; generating, by the processing device, a trip map based on the plurality of parameters and the overall condition for the predetermined interval of the wellbore, the trip map being a visual representation of the plurality of parameters and the overall condition, the trip map comprising: a background shape including the plurality of parameters and the overall condition positioned angularly around the background shape; a polygon positioned on the background shape, the polygon including a plurality of corners, each corner of the plurality of corners corresponding to the overall condition or to different parameters of the plurality of parameters, each corner positioned at different radial positions of the background shape based on the at least one status; and outputting, by a user interface, the trip map that is usable to adjust the tripping operation. Example 11 is the method of example 10, wherein the plurality of parameters includes tripping operational set point parameters for planning the tripping operation, control parameters for controlling the tripping operation, and wellbore parameters for monitoring wellbore conditions during the tripping operation. Example 12 is the method of example 10, wherein outputting the trip map further comprises: generating, by the processing device, visual indicators for the plurality of parameters in the trip map, the visual indicators connecting the plurality of corners of the polygon to the plurality of parameters; determining, by the processing device, optimized values for the plurality of parameters based on theoretical data; determining, by the processing device, measured values for the plurality of parameters based on the input data; determining, by the processing device, the at least one status of the plurality of parameters based on differences between the optimized values and the measured values; generating, by the processing device, at least one circular region on the trip map corresponding to the at least one status of the plurality of parameters; and providing, via the user interface, the trip map with the polygon and the visual indicators for the plurality of parameters in the at least one circular region for adjusting the tripping operation. Example 13 is the method of example 10, further comprising outputting an overall condition plot by: determining, by the processing device, the overall condition for the predetermined interval by combining values of the plurality of parameters to generate a value for the overall condition; plotting, by the processing device, the overall condition at a depth corresponding to the predetermined interval; generating, by the processing device, a trendline by connecting a plurality of overall conditions with the trendline over a certain depth; and providing, via the user interface, the trendline. Example 14 is the method of example 10, wherein determining the overall condition comprises: determining, by the processing device, an optimized value for the overall condition based on theoretical data; determining, by the processing device, a measured value for the overall condition based on the plurality of parameters; and comparing, by the processing device, the optimized value of the overall condition to the measured value of the overall condition. Example 15 is the method of example 10, further comprising adjusting the tripping operation by adjusting, by the processing device, at least one aspect of the tripping operation, the at least one aspect including a speed of the tripping operation, a direction of the tripping operation, or stopping or resuming the tripping operation. Example 16 is a non-transitory computer-readable medium comprising instructions that are executable by a processing device for causing the processing device to perform operations comprising: receiving input data for a predetermined interval of a wellbore from a downhole tool deployable in the wellbore, the input data usable to determine a plurality of parameters relating to a tripping operation with respect to the wellbore; determining an overall condition for the predetermined interval of the wellbore during the tripping operation based on the plurality of parameters; determining at least one status for each parameter of the plurality of parameters and for the overall condition based on a difference between at least one value for the plurality of parameters or the overall condition and a corresponding optimized value; generating a trip map based on the plurality of parameters and the overall condition for the predetermined interval of the wellbore, the trip map being a visual representation of the plurality of parameters and the overall condition, the trip map comprising: a background shape including the plurality of parameters and the overall condition positioned angularly around the background shape; a polygon positioned on the background shape, the polygon including a plurality of corners, each corner of the plurality of corners corresponding to the overall condition or to different parameters of the plurality of parameters, each corner positioned at different radial positions of the background shape based on the at least one status; and outputting, by a user interface, the trip map that is usable to adjust the tripping operation. Example 17 is the non-transitory computer-readable medium of example 16, further comprising the operation of adjusting the tripping operation by adjusting at least one aspect of the tripping operation, the at least one aspect including a speed of the tripping operation, a direction of the tripping operation, or stopping or resuming the tripping operation. Example 18 is the non-transitory computer-readable medium of example 16, wherein the plurality of parameters includes swab influx, swab pressure, runnability index, equivalent circulating density, equivalent mud weight, optimum speed, static drag, and pore pressure. Example 19 is the non-transitory computer-readable medium of example 16, further comprising adjusting the tripping operation autonomously by: receiving the trip map or an overall condition plot; determining an adjustment to the tripping operation based on the trip map or the overall condition plot; and adjusting the tripping operation based on the adjustment. Example 20 is the non-transitory computer-readable medium of example 16, wherein the trip map is a three-dimensional trip map, wherein the three-dimensional trip map is a cylindrical visual representation of the plurality of parameters and the overall condition, and wherein the three-dimensional trip map includes a length of the predetermined interval. The foregoing description of certain examples, including illustrated examples, has been presented only for the purpose of illustration and description and is not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Numerous modifications, adaptations, and uses thereof will be apparent to those skilled in the art without departing from the scope of the disclosure. | 54,390 |
11859486 | It is noted that the drawings are illustrative and are not necessarily to scale. DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS OF THE DISCLOSURE Example embodiments consistent with the teachings included in the present disclosure are directed to a system10and method100using a sensor embedded in a flexible tape which monitors for corrosion of a structure, such as a conveyance line in a well or pipeline. As shown inFIG.1, the system10includes a spool12of the flexible tape14having the sensor embedded therein. The flexible tape14advances from the spool12adjacent to a data acquisition unit16. The data acquisition unit16is a hardware processor storing code therein configured to acquire sensor data from the sensor embedded in the flexible tape14. The flexible tape14further advances into a well18along a conveyance line20that is shown extending into a borehole of the well18. The conveyance line can be a wireline, slickline, fiber-line, drill-pipe, tubing, coiled-tubing, or other structures extending through a well, pipeline, or casing. The conveyance line20ends at a terminating member22. The terminating member22can be a weight bar. Alternatively, the terminating member22can be a logging tool. Still further, the terminating member22can be a memory sub. In any of these arrangements, the terminating member has a weight to assist the tape in advancing down into the borehole. In an alternative embodiment illustrated inFIG.2, the system30includes sensor spools32,34, with a sensor tape36advancing from the sensor spool32to the sensor spool34through the use of at least one spool driver38(only one illustrated), but a driver can be provided for each sensor spool. The sensor tape36is a flexible tape having a sensor embedded therein. The sensor tape36with the sensor is advanced to a sensor window40to be positioned adjacent to an element under test42. The sensor on the sensor tape36generates sensor data corresponding to the state of the element under test, such as corrosion. The corrosion can be detected by the presence of hydrogen (H). Also, the corrosion can be detected by the presence of carbon dioxide (CO2). In addition, the corrosion can be detected by the presence of hydrogen sulfide (H2S). Furthermore, the corrosion can be detected by the presence of chlorine (Cl). Still further, the corrosion can be detected by the presence of iron (Fe). Common to both arrangements ofFIGS.1and2, such sensor data is sent to a data acquisition unit44. The data acquisition unit44is a hardware processor storing code therein configured to acquire the sensor data from the sensor embedded in the flexible sensor tape36. The data acquisition unit44transmits the sensor data to a data analysis unit46. The data analysis unit46is a hardware processor storing code therein configured to generate an alert from the sensor data. The data analysis unit46formats the alert to be in a predetermined communication format. The data analysis unit46transmits the formatted alert to a data communication unit48. The data communication unit48is a hardware processor storing code therein and configured to output the alert to an external system. The external system is an output device configured to output the alert or the sensor data. The external system can be a surface system50. The surface system50can further process the alert or the sensor data. Alternatively, the external system can be a memory52configured to store the alert or the sensor data to be available for later processing and analysis. Referring toFIG.3, the sensor62comprises a chemical sensor. In certain embodiments, the chemical sensor can be made of synthetic zinc oxide (ZnO) nanostructures that are grown on a zeolite substrate to detect corrosion species. Alternatively, the sensor62can be an organic sensor. The organic sensor can be disposed on organic semiconductors or conductive organic materials. Furthermore, the sensor62can be a polyethylene terephthalate (PET) sensor. The PET sensor can detect gases. As shown inFIG.4, the sensor tape36is a flexible tape having at least one sensor62of one or multiple types embedded therein. Referring toFIGS.5-8, the sensor tape36can be spooled on the spools32,34to advance the tape36to position the at least one sensor62adjacent to the sensor window40. As shown in the schematic views provided inFIGS.5-8, the tape advances from the spool32in a direction relative to the structure such as the element under test42. As illustrated inFIG.5, the direction is a horizontal direction. Alternatively, the direction is an inline-longitudinal direction. As illustrated inFIG.6, the direction is a vertical direction. Alternatively, the direction is an inline-azimuthal direction. As shown inFIGS.7-8, direction is a diagonal direction. As illustrated inFIG.7, the direction is a parallel-longitudinal direction. As illustrated inFIG.8, the direction is a parallel-azimuthal direction. Referring toFIG.9, a logging tool70has a structure72as the element under test. The structure72can optionally rotate about an axis74. As the structure rotates, various sensors62on respective tapes36are positioned horizontally adjacent to the surface of the structure72to detect corrosion at specific locations on the structure72. In alternative embodiments, as shown inFIGS.10-11the tapes36having sensors62embedded therein can be spooled about the surface of the structures to detect corrosion. Referring toFIG.10, a logging tool80can have a structure82with tape36spooled helically adjacent to the structure82. Referring toFIG.11, a logging tool90can have a structure92with different tapes94,96,98spooled vertically adjacent to the structure92. As with the logging tool70inFIG.9, the logging tools80,90inFIGS.10-11, respectively, can rotate. Such rotation allows the sensors62to be positioned adjacent to different regions on the structures82,92, to detect for corrosion at different locations on the logging tools80,90, respectively. As shown inFIG.12, the method100of operation of the systems10,30include moving or advancing a tape36having embedded sensors62out of or from a spool32in step102, and moving or positioning the embedded sensor62on the tape36to a sensor window40adjacent to an element42under test in step104. Then data is acquired from the embedded sensor62at the sensor window40in step106, and the acquired data is analyzed in step108. The analyzed data is formatted in step110in a conventional manner to meet the requirements of an external system. For instance, the data can be formatted into a spreadsheet and saved so as to be compatible with Microsoft Excel, or saved as a comma-separated values table, text file, and so on. Alternatively, the data can be saved in data value pairs and saved in a list. The formatted data is transmitted to an external system50or memory52in step112. The method100then generates and outputs an alert of corrosion of the element42under test using the formatted data in step114. In an alternative arrangement, the system and method described herein can have a sensor as previously described embedded in the conveyance line within a well or, alternatively, in a surface structure. In these arrangements, the sensor still monitors for corrosion of a structure, but is mounted in a different position. Portions of the methods described herein can be performed by software or firmware in machine readable form on a tangible (e.g., non-transitory) storage medium. For example, the software or firmware can be in the form of a computer program including computer program code adapted to cause the system to perform various actions described herein when the program is run on a computer or suitable hardware device, and where the computer program can be embodied on a computer readable medium. Examples of tangible storage media include computer storage devices having computer-readable media such as disks, thumb drives, flash memory, and the like, and do not include propagated signals. Propagated signals can be present in a tangible storage media. The software can be suitable for execution on a parallel processor or a serial processor such that various actions described herein can be carried out in any suitable order, or simultaneously. It is to be further understood that like or similar numerals in the drawings represent like or similar elements through the several figures, and that not all components or steps described and illustrated with reference to the figures are required for all embodiments or arrangements. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “contains”, “containing”, “includes”, “including,” “comprises”, and/or “comprising,” and variations thereof, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. Terms of orientation are used herein merely for purposes of convention and referencing and are not to be construed as limiting. However, it is recognized these terms could be used with reference to an operator or user. Accordingly, no limitations are implied or to be inferred. In addition, the use of ordinal numbers (e.g., first, second, third) is for distinction and not counting. For example, the use of “third” does not imply there is a corresponding “first” or “second.” Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” “having,” “containing,” “involving,” and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. While the disclosure has described several exemplary embodiments, it will be understood by those skilled in the art that various changes can be made, and equivalents can be substituted for elements thereof, without departing from the spirit and scope of the invention. In addition, many modifications will be appreciated by those skilled in the art to adapt a particular instrument, situation, or material to embodiments of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed, or to the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. The subject matter described above is provided by way of illustration only and should not be construed as limiting. Various modifications and changes can be made to the subject matter described herein without following the example embodiments and applications illustrated and described, and without departing from the true spirit and scope of the invention encompassed by the present disclosure, which is defined by the set of recitations in the following claims and by structures and functions or steps which are equivalent to these recitations. | 11,325 |
11859487 | DETAILED DESCRIPTION It is to be understood that the following disclosure describes many different implementations, or examples, for implementing different features of various implementations. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various implementations and/or configurations discussed. This disclosure introduces systems and methods to measure toolface angles and assess the performance of a slide drilling operation, such as by measuring average toolface angle and calculating a slide stability score. In some implementations, the slide stability score is a representation of the consistency of toolface angle or toolface stability during a portion of the drilling operation, and may be expressed as a percentage. The slide stability score may help an operator to assess the efficiency of a slide drilling operation as well as to determine the ability of the drilling system to create a curved wellbore in a slide drilling operation. Furthermore, the calculation and application of the slide stability score may help reduce the amount of sliding required during a drilling operation, which would improve the economics of drilling the well (i.e., saving time and equipment wear by reducing tortuosity of the wellbore) and as well as the long-term economics of the completed well (i.e., increasing pumping production from the well by reducing unnecessary curvature from slide drilling). Referring toFIG.1, illustrated is a schematic view of apparatus100demonstrating one or more aspects of the present disclosure. The apparatus100is or includes a land-based drilling rig. However, one or more aspects of the present disclosure are applicable or readily adaptable to any type of drilling rig, such as jack-up rigs, semisubmersibles, drill ships, coil tubing rigs, well service rigs adapted for drilling and/or re-entry operations, and casing drilling rigs, among others within the scope of the present disclosure. Apparatus100includes a mast105supporting lifting gear above a rig floor110. The lifting gear includes a crown block115and a traveling block120. The crown block115is coupled at or near the top of the mast105, and the traveling block120hangs from the crown block115by a drilling line125. One end of the drilling line125extends from the lifting gear to drawworks130, which is configured to reel in and out the drilling line125to cause the traveling block120to be lowered and raised relative to the rig floor110. The other end of the drilling line125, known as a dead line anchor, is anchored to a fixed position, possibly near the drawworks130or elsewhere on the rig. A hook135is attached to the bottom of the traveling block120. A top drive140is suspended from the hook135. A quill145extending from the top drive140is attached to a saver sub150, which is attached to a drill string155suspended within a wellbore160. Alternatively, the quill145may be attached to the drill string155directly. The term “quill” as used herein is not limited to a component which directly extends from the top drive, or which is otherwise conventionally referred to as a quill. For example, within the scope of the present disclosure, the “quill” may additionally or alternatively include a main shaft, a drive shaft, an output shaft, and/or another component which transfers torque, position, and/or rotation from the top drive or other rotary driving element to the drill string, at least indirectly. Nonetheless, albeit merely for the sake of clarity and conciseness, these components may be collectively referred to herein as the “quill.” The drill string155includes interconnected sections of drill pipe165, a bottom hole assembly (BHA)170, and a drill bit175. The BHA170may include stabilizers, drill collars, and/or measurement-while-drilling (MWD) or wireline conveyed instruments, among other components. In some implementations, the BHA170includes a bent housing drilling system. Implementations using bent housing drilling systems may require slide drilling techniques to execute or effect a turn using directional drilling. For the purpose of slide drilling, the bent housing drilling systems may include a down hole motor with a bent housing or other bend component operable to create an off-center departure of the bit from the center line of the wellbore. The direction of this departure from the centerline in a plane normal to the centerline is referred to as the “toolface angle.” The drill bit175, which may also be referred to herein as a “tool,” may have a “toolface,” connected to the bottom of the BHA170or otherwise attached to the drill string155. One or more pumps180may deliver drilling fluid to the drill string155through a hose or other conduit185, which may be connected to the top drive140. The down hole MWD or wireline conveyed instruments may be configured for the evaluation of physical properties such as pressure, temperature, torque, weight-on-bit (WOB), vibration, inclination, azimuth, toolface orientation in three-dimensional space, and/or other down hole parameters. These measurements may be made down hole, stored in memory, such as solid-state memory, for some period of time, and downloaded from the instrument(s) when at the surface and/or transmitted in real-time to the surface. Data transmission methods may include, for example, digitally encoding data and transmitting the encoded data to the surface, possibly as pressure pulses in the drilling fluid or mud system, acoustic transmission through the drill string155, electronic transmission through a wireline or wired pipe, transmission as electromagnetic pulses, among other methods. The MWD sensors or detectors and/or other portions of the BHA170may have the ability to store measurements for later retrieval via wireline and/or when the BHA170is tripped out of the wellbore160. In an exemplary implementation, the apparatus100may also include a rotating blow-out preventer (BOP)158that may assist when the well160is being drilled utilizing under-balanced or managed-pressure drilling methods. The apparatus100may also include a surface casing annular pressure sensor159configured to detect the pressure in an annulus defined between, for example, the wellbore160(or casing therein) and the drill string155. In the exemplary implementation depicted inFIG.1, the top drive140is utilized to impart rotary motion to the drill string155. However, aspects of the present disclosure are also applicable or readily adaptable to implementations utilizing other drive systems, such as a power swivel, a rotary table, a coiled tubing unit, a down hole motor, and/or a conventional rotary rig, among others. The apparatus100also includes a controller190configured to control or assist in the control of one or more components of the apparatus100. For example, the controller190may be configured to transmit operational control signals to the drawworks130, the top drive140, the BHA170and/or the pump180. The controller190may be a stand-alone component installed near the mast105and/or other components of the apparatus100. In an exemplary implementation, the controller190includes one or more systems located in a control room in communication with the apparatus100, such as the general purpose shelter often referred to as the “doghouse” serving as a combination tool shed, office, communications center, and general meeting place. The controller190may be configured to transmit the operational control signals to the drawworks130, the top drive140, the BHA170, and/or the pump180via wired or wireless transmission devices which, for the sake of clarity, are not depicted inFIG.1. The controller190is also configured to receive electronic signals via wired or wireless transmission devices (also not shown inFIG.1) from a variety of sensors included in the apparatus100, where each sensor is configured to detect an operational characteristic or parameter. Depending on the implementation, the apparatus100may include a down hole annular pressure sensor170acoupled to or otherwise associated with the BHA170. The down hole annular pressure sensor170amay be configured to detect a pressure value or range in an annulus shaped region defined between the external surface of the BHA170and the internal diameter of the wellbore160, which may also be referred to as the casing pressure, down hole casing pressure, MWD casing pressure, or down hole annular pressure. Measurements from the down hole annular pressure sensor170amay include both static annular pressure (pumps off) and active annular pressure (pumps on). It is noted that the meaning of the word “detecting,” in the context of the present disclosure, may include detecting, sensing, measuring, calculating, and/or otherwise obtaining data. Similarly, the meaning of the word “detect” in the context of the present disclosure may include detect, sense, measure, calculate, and/or otherwise obtain data. The apparatus100may additionally or alternatively include a shock/vibration sensor170bthat is configured to detect shock and/or vibration in the BHA170. The apparatus100may additionally or alternatively include a mud motor pressure sensor172athat is configured to detect a pressure differential value or range across one or more motors172of the BHA170. The one or more motors172may each be or include a positive displacement drilling motor that uses hydraulic power of the drilling fluid to drive the drill bit175, also known as a mud motor. One or more torque sensors172bmay also be included in the BHA170for sending data to the controller190that is indicative of the torque applied to the drill bit175by the one or more motors172. The apparatus100may additionally or alternatively include a toolface sensor170cconfigured to detect the current toolface orientation. The toolface sensor170cmay be or include a conventional or future-developed magnetic toolface sensor which detects toolface orientation relative to magnetic north. Alternatively, or additionally, the toolface sensor170cmay be or include a conventional or future-developed gravity toolface sensor which detects toolface orientation relative to the Earth's gravitational field. The toolface sensor170cmay also, or alternatively, be or include a conventional or future-developed gyro sensor. The apparatus100may additionally or alternatively include a WOB sensor170dintegral to the BHA170and configured to detect WOB at or near the BHA170. The apparatus100may additionally or alternatively include a torque sensor140acoupled to or otherwise associated with the top drive140. The torque sensor140amay alternatively be located in or associated with the BHA170. The torque sensor140amay be configured to detect a value or range of the torsion of the quill145and/or the drill string155(e.g., in response to operational forces acting on the drill string). The top drive140may additionally or alternatively include or otherwise be associated with a speed sensor140bconfigured to detect a value or range of the rotary speed of the quill145. The top drive140, drawworks130, crown or traveling block, drilling line or dead line anchor may additionally or alternatively include or otherwise be associated with a WOB sensor140c(WOB calculated from a hook load sensor that can be based on active and static hook load, e.g., one or more sensors installed somewhere in the load path mechanisms to detect and calculate WOB, which can vary from rig to rig) different from the WOB sensor170d. The WOB sensor140cmay be configured to detect a WOB value or range, where such detection may be performed at the top drive140, drawworks130, or other component of the apparatus100. The detection performed by the sensors described herein may be performed once, continuously, periodically, and/or at random intervals. The detection may be manually triggered by an operator or other person accessing a human-machine interface (HMI), or automatically triggered by, for example, a triggering characteristic or parameter satisfying a predetermined condition (e.g., expiration of a time period, drilling progress reaching a predetermined depth, drill bit usage reaching a predetermined amount, etc.). Such sensors and/or other detection elements may include one or more interfaces which may be local at the well/rig site or located at another, remote location with a network link to the system. Referring toFIG.2, illustrated is a block diagram of an apparatus200according to one or more aspects of the present disclosure. The apparatus200includes a user interface260, a bottom hole assembly (BHA)210, a drive system230, a drawworks240, and a directional planning and monitoring controller252. The apparatus200may be implemented within the environment and/or apparatus shown inFIG.1. For example, the BHA210may be substantially similar to or may be the BHA170shown inFIG.1, the drive system230may be substantially similar to the top drive140shown inFIG.1, the drawworks240may be substantially similar to the drawworks130shown inFIG.1, and the directional planning and monitoring controller252may be substantially similar to the controller190shown inFIG.1. The user interface260and the directional planning and monitoring controller252may be discrete components that are interconnected via wired or wireless devices. Alternatively, the user interface260and the directional planning and monitoring controller252may be integral components of a single system or controller250, as indicated by the dashed lines inFIG.2. The user interface260may include a data input device266that permits a user to input one or more toolface set points. This may also include inputting other set points, limits, and other input data. The data input device266may include a keypad, voice-recognition apparatus, dial, button, switch, slide selector, toggle, joystick, mouse, data base and/or other conventional or future-developed data input device. Such data input device266may support data input from local and/or remote locations. Alternatively, or additionally, the data input device266may include one or more devices for providing a user selection of predetermined toolface set point values or ranges, such as via one or more drop-down menus or allows a user to enter desired setpoint values or ranges. The toolface set point data may also or alternatively be selected by the directional planning and monitoring controller252via the execution of one or more database look-up procedures. In general, the data input device266and/or other components within the scope of the present disclosure support operation and/or monitoring from stations on the rig site as well as one or more remote locations with a communications link to the system, network, local area network (LAN), wide area network (WAN), Internet, satellite-link, and/or radio, among other communication types. The user interface260may also include a survey input device268. The survey input device268may include information gathered from sensors regarding the orientation and location of the BHA210. In some implementations, survey input device268is automatically entered into the user interface at regular intervals. The user interface260may also include a display device261arranged to present visualizations of a down hole environment, such as a two-dimensional visualization and/or a three-dimensional visualization. The display device261may be used for visually presenting information to the user in textual, graphic, or video form. Depending on the implementation, the display device261may include, for example, an LED or LCD display computer monitor, touchscreen display, television display, a projector, or other display device. Some examples of information that may be shown on the display device261will be discussed in further detail with reference toFIG.3. The BHA210may include a MWD casing pressure sensor212that is configured to detect an annular pressure value or range at or near the MWD portion of the BHA210, and that may be substantially similar to the down hole annular pressure sensor170ashown inFIG.1. The casing pressure data detected via the MWD casing pressure sensor212may be sent via electronic signal to the directional planning and monitoring controller252via wired or wireless transmission. The BHA210may also include an MWD shock/vibration sensor214that is configured to detect shock and/or vibration in the MWD portion of the BHA210, and that may be substantially similar to the shock/vibration sensor170bshown inFIG.1. The shock/vibration data detected via the MWD shock/vibration sensor214may be sent via electronic signal to the directional planning and monitoring controller252via wired or wireless transmission. The BHA210may also include a mud motor pressure sensor216that is configured to detect a pressure differential value or range across the mud motor of the BHA210, and that may be substantially similar to the mud motor pressure sensor172ashown inFIG.1. The pressure differential data detected via the mud motor pressure sensor216may be sent via electronic signal to the directional planning and monitoring controller252via wired or wireless transmission. The mud motor pressure may be alternatively or additionally calculated, detected, or otherwise determined at the surface, such as by calculating the difference between the surface standpipe pressure just off-bottom and pressure once the bit touches bottom and starts drilling and experiencing torque. The BHA210may also include a magnetic toolface sensor218and a gravity toolface sensor220that are cooperatively configured to detect the current toolface, and that collectively may be substantially similar to the toolface sensor170cshown inFIG.1. The magnetic toolface sensor218may be or include a conventional or future-developed magnetic toolface sensor which detects toolface orientation relative to magnetic north. The gravity toolface sensor220may be or include a conventional or future-developed gravity toolface sensor which detects toolface orientation relative to the Earth's gravitational field. In an exemplary implementation, the magnetic toolface sensor218may detect the current toolface when the end of the wellbore is less than about 7° from vertical, and the gravity toolface sensor220may detect the current toolface when the end of the wellbore is greater than about 7° from vertical. However, other toolface sensors may also be utilized within the scope of the present disclosure, including non-magnetic toolface sensors and non-gravitational inclination sensors. In any case, the toolface orientation detected via the one or more toolface sensors (e.g., magnetic toolface sensor218and/or gravity toolface sensor220) may be sent via electronic signal to the directional planning and monitoring controller252via wired or wireless transmission. The BHA210may also include an MWD torque sensor222that is configured to detect a value or range of values for torque applied to the bit by the motor(s) of the BHA210, and that may be substantially similar to the torque sensor172bshown inFIG.1. The torque data detected via the MWD torque sensor222may be sent via electronic signal to the directional planning and monitoring controller252via wired or wireless transmission. The BHA210may also include a MWD WOB sensor224that is configured to detect a value or range of values for WOB at or near the BHA210, and that may be substantially similar to the WOB sensor170dshown inFIG.1. The WOB data detected via the MWD WOB sensor224may be sent via electronic signal to the directional planning and monitoring controller252via wired or wireless transmission. Depending upon the implementation, the BHA210may include one or more directional drilling components226. These components may include bent housing system components. In some implementations, the directional drilling components226may include a drilling motor that forms part of the BHA210. The drawworks240may include a controller242and/or other devices for controlling feed-out and/or feed-in of a drilling line (such as the drilling line125shown inFIG.1). Such control may include rotary control of the drawworks (in versus out) to control the height or position of the hook, and may also include control of the rate the hook ascends or descends. The drive system230may form the top drive140and may include a surface torque sensor232that is configured to detect a value or range of the reactive torsion of the quill or drill string, much the same as the torque sensor140ashown inFIG.1. The drive system230also includes a quill position sensor234that is configured to detect a value or range of the rotary position of the quill, such as relative to true north or another stationary reference. The surface torsion and quill position data detected via the surface torque sensor232and the quill position sensor234, respectively, may be sent via electronic signal to the directional planning and monitoring controller252via wired or wireless transmission. The drive system230also includes a controller236and/or other devices for controlling the rotary position, speed and direction of the quill or other drill string component coupled to the drive system230(such as the quill145shown inFIG.1). The directional planning and monitoring controller252may be configured to receive one or more of the above-described parameters from the user interface260, the BHA210, the drawworks240, and/or the drive system230, and utilize such parameters to continuously, periodically, or otherwise determine the current toolface orientation. The directional planning and monitoring controller252may be further configured to generate a control signal, such as via intelligent adaptive control, and provide the control signal to the drive system230and/or the drawworks240to adjust and/or maintain the toolface orientation. For example, the directional planning and monitoring controller252may provide one or more signals to the drive system230and/or the drawworks240to increase or decrease WOB and/or quill position, such as may be required to accurately “steer” the drilling operation. The directional planning and monitoring controller252may also be configured to provide signals to the RSS components to change the RSS drilling control parameters. FIG.3shows a schematic view of a human-machine interface (HMI)300according to one or more aspects of the present disclosure. The HMI300may be utilized by a human operator during directional and/or other drilling operations to monitor the relationship between toolface orientation and quill position. The HMI300may include aspects of the ROCKit® HMI display of Canrig Drilling Technology, LTD. In an exemplary implementation, the HMI300is one of several display screens selectably viewable by the user during drilling operations, and may be included as or within the human-machine interfaces, drilling operations and/or drilling apparatus described in the systems herein. The HMI300may also be implemented as a series of instructions recorded on a computer-readable medium, such as described in one or more of these references. In some implementations, the HMI300is the two-dimensional visualization262ofFIG.2. The HMI300is used by a user, who may be a directional driller operator, while drilling to monitor the status and direction of drilling using the BHA. The directional planning and monitoring controller252ofFIG.2may drive one or more other human-machine interfaces during drilling operation and may be configured to also display the HMI300on the display device261. The directional planning and monitoring controller252driving the HMI300may include a “survey” or other data channel, or otherwise includes devices for receiving and/or reading sensor data relayed from the BHA170, a measurement-while-drilling (MWD) assembly, a RSS assembly, and/or other drilling parameter measurement devices, where such relay may be via the Wellsite Information Transfer Standard (WITS), WITS Markup Language (WITS ML), and/or another data transfer protocol. Such electronic data may include gravity-based toolface orientation data, magnetic-based toolface orientation data, azimuth toolface orientation data, and/or inclination toolface orientation data, among others. As shown inFIG.3, the HMI300may be depicted as substantially resembling a dial or target shape302having a plurality of concentric nested rings. The HMI300also includes a pointer330representing the quill position. Symbols for magnetic toolface data and gravity toolface data symbols may also be shown. In the example ofFIG.3, gravity toolface angles are depicted as toolface symbols306. In one exemplary implementation, the symbols for the magnetic toolface data are shown as circles and the symbols for the gravity toolface data are shown as rectangles. Of course, other shapes may be utilized within the scope of the present disclosure. The toolface symbols306may also or alternatively be distinguished from one another via color, size, flashing, flashing rate, and/or other graphic elements. In some implementations, the toolface symbols306may indicate only the most recent toolface measurements. However, as in the exemplary implementation shown inFIG.3, the HMI300may include a historical representation of the toolface measurements, such that the most recent measurement and a plurality of immediately prior measurements are displayed. Thus, for example, each ring in the HMI300may represent a measurement iteration or count, or a predetermined time interval, or otherwise indicate the historical relation between the most recent measurement(s) and prior measurement(s). In the exemplary implementation shown inFIG.3, there are five such rings in the dial302(the outermost ring being reserved for other data indicia), with each ring representing a data measurement or relay iteration or count. The toolface symbols306may each include a number indicating the relative age of each measurement. In the present example, the outermost triangle of the toolface symbols306corresponds to the most recent measurement. After the most recent measurement, previous measurements are positioned incrementally towards the center of the dial302. In other implementations, color, shape, and/or other indicia may graphically depict the relative age of measurement. Although not depicted as such inFIG.3, this concept may also be employed to historically depict the quill position data. In some implementations, measurements are taken every 10 seconds, although depending on the implementation, measurements may be taken at time periods ranging from every second to every half-hour. Other time periods are also contemplated. The HMI300may also include a number of textual and/or other types of indicators316,318,320displaying parameters of the current or most recent toolface orientation. For example, indicator316shows the inclination of the wellbore, measured by the survey instrument, as 91.25°. Indicator318shows the azimuth of the wellbore, measured by the survey instrument as 354°. Indicator320shows the hole depth of the wellbore as 8949.2 feet. In the exemplary implementation shown, the HMI300may include a programmable advisory width. In the example ofFIG.3, this value is depicted by advisory width sector304with an adjustable angular width corresponding to an angular setting shown in the corresponding indicator312, in this case 45°. The advisory width is a visual indicator providing the user with a range of acceptable deviation from the advisory toolface direction. In the example ofFIG.3, the toolface symbols306all lie within the advisory width sector304, meaning that the user is operating within acceptable deviation limits from the advisory toolface direction. Indicator310gives an advisory toolface direction, corresponding to line322. The advisory toolface direction represents an optimal direction towards the drill plan. Indicator308, shown inFIG.3as an arrow on the outermost edge of the dial302, is an indicator of the overall resultant direction of travel of the toolface. This indicator308may present an orientation that averages the values of other indicators316,318,320. Other values and depictions are included on the HMI300that are not discussed herein. These other values include the time and date of drilling, aspects relating to the operation of the drill, and other received sensor data. FIGS.4A and4Bshow exemplary representations of a down hole environment400including a down hole portion of a drilling system including a BHA406and drill string408. In some implementations, instructions to drive the BHA406to various drilling targets or steering objective locations in the down hole environment400may be implemented to drive the BHA406through the down hole environment400. The drill string408may be made up of a number of tubulars. The BHA406and drill string408correspond to the BHA170and drill string155inFIG.1, and may form a portion of the drilling apparatus100described with reference toFIGS.1and2.FIGS.4A and4Bshow the BHA406and drill string408within a drilled bore, with an end of the drilled bore designated by the reference number404, also referred to as a bore end404. The bore end404may represent the bottom of a wellbore402drilled by the BHA406. In some implementations, the bore end404corresponds to the location of the BHA406, and the location of the bore end404may be determined by determining the location of the BHA406. In some implementations, a toolface direction or angle may be measured relative to a plane403normal to a longitudinal axis of the BHA406. In the example ofFIG.4A, the toolface direction or angle is illustrated by angle α. As a slide is effected, the BHA406is driven along a distance D1(i.e., well path) to a new bore end420. In some implementations, the toolface angle is chose as a constant value for a portion of the drilling operation (i.e., angle α remains constant along distance D1). The toolface angle may be measured continuously or at intervals during the drilling operation. For example, the toolface angle may be measured, for example, every 15-20 seconds. In other implementations, the toolface angle is measured every 1-5 sections, every 5-10 seconds, or every 20-30 seconds. Other ranges, more frequent and less frequent are also contemplated. The toolface angle may be transmitted to a controller on the drilling rig, such as the directional planning and monitoring controller252as shown inFIG.1, and may be displayed on an HMI300as shown inFIGS.3and5. In some implementations, the toolface angle varies as the BHA406is driven during the drilling operation. For example, although angle α may be chosen as an initial toolface angle, the BHA406may be driven at angle β instead in the example shown in inFIG.4B. This may occur because of unexpected conditions downhole (such as differences in formations), wear on drilling components such as the downhole motor or drilling bit, or variation in drilling parameters such as weight on bit or pressure on the drill string. Furthermore, the toolface angle may change throughout a portion of a drilling operation. For example, the toolface angle changes to angle γ during the drilling operation shown inFIG.4B. These changes in toolface angle may cause inefficiencies in the drilling operation, such as deviation from a drilling plan (i.e., the resulting bore end420may not conform to a drilling plan in the example ofFIG.4B). Calculation of average toolface angle and calculation of slide stability may help an operator to more accurately assess and address these problems, as discussed in reference toFIGS.5and6. FIG.5shows a schematic view of an interface500according to one or more aspects of the present disclosure. The interface500may be utilized by a human operator during directional and/or other drilling operations to monitor the direction and output of the toolface. The interface500may be updated automatically with data received during a drilling operation, such as with measured toolface angles. In some implementations, the values shown on the interface500are calculated automatically by a controller, such as controller190shown inFIG.1or the directional planning and monitoring controller252as shown inFIG.2. The interface500may include a dial502including one or more unit vectors506,508representing toolface angles. The dial502may also include previously measured toolface angles (shown by triangular symbols504at 90 degrees and 110 degrees, respectively). The dial502may be configured to show a difference between planned toolface angles520and current toolface angles522. In the example ofFIG.5, the planned toolface angle520is 100 degrees and the current toolface angle522is 105 degrees, showing a deviation in toolface angle of 5 degrees. The toolface angles may be represented in other formats, such as in text format, on a scale, or by varying visual representations including different symbols, colors, patterns, and textures. By considering each measured toolface angle as a unit vector506,508, the controller may be configured to calculate slide drilling parameters such as average toolface angle, stability score, and motor output which may be displayed on the interface500. These parameters are not available on current drilling rigs. For example, calculations of average toolface using degree measurements in current drilling systems may be inaccurate. For instance, if four azimuth measurements are recorded at 355 degrees, 345 degrees, 5 degrees, and 10 degrees (all in a northerly direction) taking a standard average (i.e., adding the measurements together and dividing by four) will give an average of 173.75 degrees, which is inaccurate because it is in a southerly direction. This problem also occurs in determining stability or consistency of toolface angles. The parameters shown in the interface500may correct this problem by giving an accurate average toolface angle512as well as an accurate measurement of the consistency of toolface angles with the slide stability score510. The controller may automatically convert each measured toolface angle to a unit vector and calculate the slide stability score with the following formula: S=(sin(a)+sin(b)+…+sin(z)n)2+(cos(a)+cos(b)+…+cos(z)n)2 where S is the slide stability score, a is a first measured toolface angle in degrees, b is a second measured toolface angle in degrees, z is an nth toolface angle in degrees, and n is the number of measured toolface angles for the drilling operation. The system may automatically calculate the average toolface angle with the following formula: A=atan2(sin(a)+sin(b)+…+sin(z)n,cos(a)+cos(b)+…+cos(z)n) where A is the average toolface angle in degrees, a is a first measured toolface angle in degrees, b is a second measured toolface angle in degrees, z is an nth toolface angle in degrees, and n is the number of measured toolface angles for the drilling operation (adding 180 for negative values). In the example ofFIG.5, the controller has received three measured toolface angles530during a drilling operation which are converted to unit vectors (i.e., drilling angle1of 90 degrees, drilling angle2of 110 degrees, and drilling angle3of 105 degrees). Other numbers of drilling angles may be measured during a drilling operation, such as every 15-20 seconds. The sine and cosine values for each unit vector are then calculated. In some implementations, the sine value of each unit vector may represent departure in an East-West direction (i.e., East being positive and West being negative), and the cosine value of each unit vector may represent departure in a North-South direction (i.e., North being positive and South being negative). The sine values of all toolface angles are all added together and divided by the total number of toolface angles. The cosine values are likewise added together and divided by the total number of toolface angles as well. In the example ofFIG.5, the following values would be calculated by the controller: sin(90)+sin(110)+sin(105)3=0.969cos(90)+cos(110)+cos(105)3=-0.200 The above values represent the average East-West deviation and average North-South deviation of the measured toolface angles, respectively. To calculate the average toolface angle, the controller may take the inverse tangent of the averaged sine and cosine values: atan 2(−0.200, 0.969)=101.7 degrees. The calculated average toolface angle512may be displayed on the interface500as shown inFIG.5. The slide stability score may also be calculated by taking the square root of the product of the averaged sine and cosine values, squared, as shown below: S=√{square root over ((0.969)2+(−0.200)2)}=0.989. Since the calculated slide stability score S will always be between 0 and 1 (i.e., all angles are measured between 0 and 360 degrees), multiplying the above result by 100 gives a slide stability score510as a percentage (S=98.9%). The calculated slide stability score510may be automatically calculated based on the received toolface angles and displayed on the interface500, as shown inFIG.5. The slide stability score510may be used to assess the performance of drilling equipment as well as assess the theoretical curvature of a directional motor such that the length of sliding in subsequent drilling operations may be more accurately calculated. Values for planned motor output540and adjusted motor output542may also be displayed on the interface500. In some implementations, the planned motor output is the ability of the drilling equipment to produce curvature in the well bore under stable conditions. The planned motor output may be measured in units of degrees per distance. In the example ofFIG.5, the planned motor output is 10.5 degrees per hundred feet, meaning that under ideal conditions, the drilling rig is able to produce a maximum curvature of 10.5 degrees per 100 feet of wellbore. The slide stability score510, as calculated above, may be used to estimate the actual (i.e., adjusted) motor output542. In this case, the planned motor output540is multiplied by the slide stability score510to calculate the adjusted motor output542: 0.989*(10.5 degrees/100 feet)=10.385 degrees/100 feet. The adjusted motor output542may be displayed on the interface500as shown. The adjusted motor output542may be used by an operator to adjust drill plans and avoid drilling errors. FIG.6is a flow chart showing a method600of measuring toolface angles, calculating a slide steering stability score, and steering a BHA. It is understood that additional steps can be provided before, during, and after the steps of method600, and that some of the steps described can be replaced or eliminated for other implementations of the method600. In particular, any of the control systems disclosed herein, including those ofFIGS.1and2, and the displays ofFIGS.3and5, may be used to carry out the method600. At step602, the method600may include inputting a drill plan for a drilling operation. This may be accomplished by entering location and orientation coordinates into a controller of a drilling system such as the directional planning and monitoring controller252discussed with reference toFIG.2. The drill plan may also be entered via the user interface, and/or downloaded or transferred to directional planning and monitoring controller252. The directional planning and monitoring controller252may therefore receive the drill plan directly from the user interface or a network or disk transfer or from some other location. In some implementations, the drill plan includes one or more slide drilling operations with at least one planned toolface angle. For example, the interface500ofFIG.5includes a planned toolface angle of 100 degrees for a portion of a slide drilling operation. The drill plan may include effecting a number of planned toolface angles for various portions of a drill operation. For example, a drill plan may include drilling down 1000 feet, effecting a 5 degree toolface angle, sliding for 100 feet, then effecting a 10 degree toolface angle and sliding for 200 feet. At step604, the method600may include effecting a planned toolface angle during the drilling operation. This may include adjusting the drill string using the top drive to rotate the bent motor of the BHA of the directional drilling system to the planned toolface angle. When the actual toolface angle corresponds to the planned toolface angle, then the driller may begin the sliding operation. At step606, the method600may include measuring a toolface angle for one or more segments of the sliding operation. Some drill plans include curves that are followed by the BHA by dividing the curve into segments. The toolface angle may be measured with respect to a plane normal to the longitudinal axis of the BHA. In some implementations, the toolface angle is measured with one or more sensors on the drilling rig, such as along the drill string or on the BHA. For example, a combination of controllers, such as those inFIG.2, may receive sensor data from a number of sensors via electronic communication. The controllers may then transmit the data to a central location for processing such as the directional planning and monitoring controller252. The toolface angle measurement may be transmitted to a controller which may convert the angle to a unit vector. Other toolface angles may also be measured and transmitted during the drilling operation either continuously or at regular intervals. In some examples, the toolface angles may be measured and transmitted, for example only, every 15-20 seconds or every 10 feet of well bore. In some implementations, the toolface angle of the BHA is measured and transmitted in real time. The change in toolface angle may represent a deviation from the planned toolface angle and may occur because of unexpected formations, problems with drilling equipment, or varying parameters in the drilling equipment. At step608, the method600may include calculating an average toolface angle using the one or more measured toolface angles captured over time or distance. In some implementations, all measured toolface angles for a drilling operation may be received by the controller and stored in memory. To calculate the average toolface angle, the controller may automatically calculate the sum of the sine values of the toolface angles and the sum of the cosine values of the toolface angles and divide these values by the number of measured toolface angles. The controller may then take the inverse tangent of the averaged sine and cosine values. as discussed above in reference toFIG.5, the average toolface angle may be calculated using the following example formula: A=atan2(sin(a)+sin(b)+…+sin(z)n,cos(a)+cos(b)+…+cos(z)n) where A is the average toolface angle in degrees, a is a first measured toolface angle in degrees, b is a second measured toolface angle in degrees, z is an nth drilling angle in degrees, and n is the number of measured toolface angles for the drilling operation (adding 180 for negative values). The average toolface angle may be automatically calculated by the controller and stored in a memory by the controller. At step610, the method600may include calculating a slide stability score based on the received toolface angles. The slide stability score may represent a consistency of the toolface angle or a stability of the toolface during a drilling operation. As discussed above, in one example, the slide stability score may be calculated using the following formula: S=(sin(a)+sin(b)+…+sin(z)n)2+(cos(a)+cos(b)+…+cos(z)n)2 where S is the stability score, a is a first measured toolface angle in degrees, b is a second measured toolface angle in degrees, z is an nth toolface angle in degrees, and n is the number of measured toolface angles for the drilling operation. In some implementations, the slide stability score is given as a percentage between 0 and 100%. The slide stability score may be automatically calculated by the controller and stored in a memory by the controller. At step612, the method600may include displaying the slide stability score on a display to a directional driller. In some implementations, the slide stability score is displayed on a display device, such as on a computer monitor. The slide stability score may be displayed along with a textual or visual representation of the measured toolface angles, as shown in the exemplary interface500ofFIG.5. The display may also include the average toolface angle, planned motor output, adjusted motor output, and other measured parameters of the drilling operation. The operator may refer to the display during a drilling operation and use the slide stability measurement as a guide as the drilling operation progresses. At step614, the method600may optionally include generating a revised toolface angle based on the measured slide stability score. For example, the controller may receive the slide stability score and assess the ability of the drilling motor to create an accurate curve in the wellbore. The controller may then compare this curvature for the drilling operation as detailed by the drill plan. In this comparison, the controller may determine an amount of deviation between the drill plan and the curvature determined by the slide stability score. (e.g., the controller may recognize that an adjusted motor output is not sufficient to produce the curvature needed for an upcoming slide drilling operation). In this case, the controller may determine an adjustment needed to correct the deviation (i.e., an amount of curvature or distance) and align the wellbore with the drill plan. The controller may then output a revised toolface angle to execute this adjustment and display this revised toolface angle to the operator. Therefore, the controller may revise the toolface angle setting to more efficiently perform the slide drilling operation and output this revised toolface angle setting to the operator. In other example, the controller may receive a low slide stability score for a particular segment of the drilling rig (e.g., a large amount of variability in toolface angle due to a problematic formation). The controller may generate a revised toolface angle to improve the drilling operation in some way based on the slide stability score, such as cutting a slide drilling operation short to avoid further drilling through the problematic formation or sliding at a later time. As before, the controller may output this revised toolface angle to the operator. At step616, the method600may include directing the BHA using the revised toolface angle setting. For example, the operator may use the revised toolface angle setting as a guide for directing the BHA in one or more future slide drilling operations. In an exemplary implementation within the scope of the present disclosure, the method600repeats after step612,614, or616, such that method flow goes back to step604and begins again. Iteration of the method600may be performed during a drilling operation. In view of all of the above and the figures, one of ordinary skill in the art will readily recognize that the present disclosure introduces a method of operating a drilling system, comprising; inputting a drill plan into a directional drilling system comprising a bottom hole assembly (BHA), the drill plan comprising a slide drilling operation; conducting the slide drilling operation, comprising: effecting an incident toolface angle of the BHA for a first distance of the slide drilling operation; measuring a first toolface angle during the slide drilling operation; comparing the measured first toolface angle to the incident toolface angle; calculating an amount of consistency of the toolface angle over the first distance of the slide drilling operation based on the comparison of the measured first toolface angle to the incident toolface angle; and displaying the amount of consistency of the toolface angle over the first distance of the slide drilling operation to an operator on a display device. In some implementations, the method further includes calculating an average toolface angle of the BHA over the first distance of the slide drilling operation, and displaying the average toolface angle of the BHA over the first distance of the slide drilling operation to the operator on the display device. The method may include measuring a second toolface angle of the BHA over a second distance of the slide drilling operation; comparing the measured second toolface angle to the incident toolface angle; and calculating a second amount of consistency of the toolface angle over the second distance during the slide drilling operation based on the comparison of the measured second toolface angle to the incident toolface angle. The second amount of consistency of the toolface angle may be given as: S=(sin(a)+sin(b)+…+sin(z)n)2+(cos(a)+cos(b)+…+cos(z)n)2 where S is the second amount of consistency of the toolface angle, a is the measured first toolface angle of the BHA in degrees, b is the measured second toolface angle of the BHA in degrees, z is a measured nth toolface angle of the BHA in degrees, and n is a number of measured toolface angles for the drilling operation. In some implementations, the method further includes determining an ideal maximum amount of curvature of a wellbore that the BHA is able to execute. The method may include calculating a modified maximum amount of curvature of the wellbore that the BHA is able to execute during the slide drilling operation using the calculated amount of consistency of the toolface angle. The method may include calculating the modified maximum amount of curvature in the wellbore by multiplying the amount of consistency of the toolface angle by the ideal maximum amount of curvature of the wellbore that the BHA is able to execute. The method may also include using the calculated amount of consistency of the toolface angle to automatically update the drill plan for the slide drilling operation. A method of measuring data of a drilling operation is also provided, including: conducting a drilling operation with a directional drilling system comprising a drilling rig, one or more sensors, a controller, and a bottom hole assembly (BHA); measuring, with the one or more sensors, one or more toolface angles of the BHA during the drilling operation; calculating, with the controller, a slide stability score for the drilling operation based on the measured one or more toolface angles, the slide stability score representing an amount of consistency of the toolface angle during the drilling operation; and displaying the slide stability score to an operator on a display device. In some implementations, the slide stability score is given as: S=(sin(a)+…+sin(z)n)2+(cos(a)+…+cos(z)n)2 where S is the slide stability score, a is a first toolface angle in degrees, z is an nth toolface angle in degrees, and n is a number of measured toolface angles for the drilling operation. The method may also include determining an initial motor yield representing an ideal maximum amount of curvature of a wellbore that the BHA is able to execute or calculating an adjusted motor yield representing the maximum amount of curvature of the wellbore that the BHA is able to execute during the drilling operation using the calculated slide stability score. The method may include calculating the adjusted motor yield by multiplying the slide stability score by the initial motor yield. The method may also include using the slide stability score to automatically update a drill plan for the drilling operation. A drilling apparatus is also provided, comprising: a drill string comprising a plurality of tubulars; a bottom hole assembly (BHA) disposed at a distal end of the drill string; a sensor system connected to the BHA and configured to measure a toolface angle of the BHA; a controller in communication with the BHA and the sensor system, wherein the controller is configured to: determine one or more toolface angles of the BHA during a drilling operation; calculate a slide stability score for the drilling operation based on the measured one or more toolface angles, the slide stability score representing an amount of consistency of the toolface angle during the drilling operation; and a display device configured to display the slide stability score to a user. In some implementations, the toolface angles are azimuth values between 0 and 360 degrees. The controller may be configured to update the slide stability score in real time based on the measured one or more toolface angles. In some implementations, the slide stability score is given as: S=(sin(a)+…+sin(z)n)2+(cos(a)+…+cos(z)n)2 where S is the slide stability score, a is a first toolface angle in degrees, z is an nth toolface angle in degrees, and n is a number of measured toolface angles for the drilling operation. The controller may be further configured to calculate an adjusted motor yield representing the maximum amount of curvature of a wellbore that the BHA is able to execute during the drilling operation using the calculated slide stability score. The controller may be further configured to use the slide stability score to automatically update a drill plan for the drilling operation. The foregoing outlines features of several implementations so that a person of ordinary skill in the art may better understand the aspects of the present disclosure. Such features may be replaced by any one of numerous equivalent alternatives, only some of which are disclosed herein. One of ordinary skill in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the implementations introduced herein. One of ordinary skill in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions and alterations herein without departing from the spirit and scope of the present disclosure. The Abstract at the end of this disclosure is provided to comply with 37 C.F.R. § 1.72(b) to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Moreover, it is the express intention of the applicant not to invoke 35 U.S.C. § 112(f) for any limitations of any of the claims herein, except for those in which the claim expressly uses the word “means” together with an associated function. | 54,900 |
11859488 | DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Unless otherwise specified, any use of any form of the terms “connect,” “engage,” “couple,” “attach,” or any other term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ”. Reference to up or down will be made for purposes of description with “up,” “upper,” “upward,” “upstream,” or “above” meaning toward the surface of the wellbore and with “down,” “lower,” “downward,” “downstream,” or “below” meaning toward the terminal end of the well, regardless of the wellbore orientation. Reference to inner or outer will be made for purposes of description with “in,” “inner,” or “inward” meaning towards the central longitudinal axis of the wellbore and/or wellbore tubular, and “out,” “outer,” or “outward” meaning towards the wellbore wall. As used herein, the term “longitudinal” or “longitudinally” refers to an axis substantially aligned with the central axis of the wellbore tubular, and “radial” or “radially” refer to a direction perpendicular to the longitudinal axis. The various characteristics mentioned above, as well as other features and characteristics described in more detail below, will be readily apparent to those skilled in the art with the aid of this disclosure upon reading the following detailed description of the embodiments, and by referring to the accompanying drawings. As utilized herein, a ‘fluid inflow event’ includes fluid inflow (e.g., any fluid inflow regardless of composition thereof), gas phase inflow, aqueous phase inflow, and/or hydrocarbon phase inflow. The fluid can comprise other components such as solid particulate matter in some embodiments, as discussed in more detail herein. Disclosed herein is a new signal processing architecture that allows for the identification of fluid inflow locations, fluid inflow discrimination in real time or near real time, and fluid flow discrimination within a conduit such as a wellbore. As utilized herein, “fluid flow discrimination” indicates an identification and/or assignment of the detected fluid flow (e.g., single phase flow, mixed phase flows, time-based slugging, altering fluid flows, etc.), gas inflow, hydrocarbon liquid (e.g., ‘oil’) inflow, and/or aqueous phase (e.g., water) inflow, including any combined or multiphase flows or inflows. The methods of this disclosure can thus be utilized to provide information on various flow events such as a fluid ingress point as well as flow regimes within a conduit rather than simply a location at which gas, water, or hydrocarbon liquid is present in the wellbore tubular (e.g., present in a flowing fluid), which can occur at any point above the ingress location as the fluid flows to the surface of the wellbore. In some embodiments, the system allows for a quantitative measurement of various fluid flows such as a relative concentration of in-well hydrocarbon liquid, water, and gas. In some instances, the systems and methods can provide information in real time or near real time. As used herein, the term “real time” refers to a time that takes into account various communication and latency delays within a system, and can include actions taken within about ten seconds, within about thirty seconds, within about a minute, within about five minutes, or within about ten minutes of the action occurring. Various sensors (e.g., distributed fiber optic acoustic sensors, etc.) can be used to obtain an acoustic sampling at various points along the wellbore. The acoustic sample can then be processed using signal processing architecture with various feature extraction techniques (e.g., spectral feature extraction techniques) to obtain a measure of one or more frequency domain features and/or combinations thereof that enable selectively extracting the acoustic signals of interest from background noise and consequently aiding in improving the accuracy of the identification of the movement of fluids (e.g., gas inflow locations, water inflow locations, hydrocarbon liquid inflow locations, etc.) in real time. While discussed in terms of being real time in some instances, the data can also be analyzed at a later time at the same location and/or a displaced location. As used herein, various frequency domain features can be obtained from the acoustic signal, and in some contexts, the frequency domain features can also be referred to herein as spectral features or spectral descriptors. In some embodiments, the spectral features can comprise other features, including those in the time domain, various transforms (e.g., wavelets, Fourier transforms, etc.), and/or those derived from portions of the acoustic signal or other sensor inputs. Such other features can be used on their own or in combination with one or more frequency domain features, including in the development of transformations of the features, as described in more detail herein. The signal processing techniques described herein can also help to address the big-data problem through intelligent extraction of data (rather than crude decimation techniques) to considerably reduce real time data volumes at the collection and processing site (e.g., by over 100 times, over 500 times, or over 1000 times, or over 10,000 times reduction, In some embodiments). In some embodiments, the acoustic signal(s) can be obtained in a manner that allows for a signal to be obtained along the entire wellbore or a portion of interest. As noted hereinabove, production logging systems utilize a production logging system (PLS) to determine flow profile in wells. However, since the PLS can be 10-20 meters long and the sensors are distributed along the length, sensors that are not at the front of the PLS are not actually taking measurements at the depth for which the measurements are recorded, and, thus, the data can be incorrect or incomplete over time. Furthermore, the flow can be altered by the mere presence of the PLS within the wellbore, so what is measured at the downstream end of the PLS is not an accurate reflection of what the profile/regime was before the tool disturbed the flow. Furthermore, as a PLS is typically run through a well once or a few times (down and then up once or a few times and out), and the sensors are exposed to the conditions at a given depth for only a very brief period of time (e.g., 4-5 seconds). Accordingly, while PLSs can provide an indication that certain events, such as downhole water inflow, may be occurring, they do not provide continuous measurements over prolonged durations of time that would be needed to study dynamic variabilities in production profiles over time. Fiber optic distributed acoustic sensors (DAS) capture acoustic signals resulting from downhole events such as gas inflow/flow, hydrocarbon liquid inflow/flow, water inflow/flow, mixed flow, and the like, as well as other background acoustics. This allows for signal processing procedures that distinguish fluid inflow and flow signals from other noise sources to properly identify each type of event. This in turn results in a need for a clearer understanding of the acoustic fingerprint of in-well event of interest (e.g., fluid inflow, water inflow, gas inflow, hydrocarbon liquid inflow, fluid flow along the tubulars, etc.) in order to be able to segregate and identify a noise resulting from an event of interest from other ambient acoustic background noise. As used herein, the resulting acoustic fingerprint of a particular event can also be referred to as a spectral signature, as described in more detail herein. Further, reducing deferrals resulting from one or more events such as water ingress and facilitating effective remediation relies upon accurate and timely decision support to inform the operator of the events. Heretofore, there has been no technology/signal processing for DAS that successfully distinguishes and extracts fluid inflow locations, let alone in near real time. The ability to identify various fluid inflow events in the wellbore may allow for various actions to be taken in response to the events. For example, a well can be shut in, production can be increased or decreased, and/or remedial measures can be taken in the wellbore, as appropriate based on the identified event(s). An effective response, when needed, benefits not just from a binary yes/no output of an identification of in-well events but also from a measure of relative amount of fluids (e.g., amount of gas inflow, amount of hydrocarbon liquid inflow, amount of water inflow, etc.) from each of the identified zones of fluid inflow so that zones contributing the greatest fluid amount(s) can be acted upon first to improve or optimize production. The systems and methods described herein can be used to identify the source of the problem, a direction and amount of flow, and/or an identification of the type of problem being faced. For example, when a water inflow location is detected, a relative flow rate of the hydrocarbon liquid at the water inflow location may allow for a determination of whether or not to remediate, the type or method of remediation, the timing for remediation, and/or deciding to alter (e.g., reduce) a production rate from the well. For example, production zones can be isolated, production assemblies can be open, closed, or choked at various levels, side wells can be drilled or isolated, and the like. Such determinations can be used to improve on the drawdown of the well while reducing the production expenses associated with various factors such as produced water. Herein described are methods and systems for identifying fluid inflow locations and/or fluid flow regimes within a conduit in the wellbore. As described herein, spectral descriptors can be used with DAS acoustic data processing to provide for downhole fluid profiling, such as fluid inflow location detection and fluid phase discrimination (e.g., the determination that the fluid at one or more locations such as the detected fluid inflow location comprises gas inflow, hydrocarbon liquid inflow, aqueous phase inflow, a combined fluid flow, and/or a time varying fluid flow such as slugging single or multiphase flow). In some embodiments, a fluid flow model can be used for inflow fluid phase discrimination to determine at least one of a gas phase inflow, an aqueous phase inflow, a hydrocarbon liquid phase inflow, and various combinational flow regimes. In some embodiments, the same or a different fluid flow model can be used for fluid flow phase discrimination to determine the composition of fluid flowing in a conduit. A method of developing a suitable fluid inflow/flow model is also provided herein. Application of the signal processing techniques and fluid flow model with DAS for downhole surveillance can provide a number of benefits including improving reservoir recovery by monitoring efficient drainage of reserves through downhole fluid surveillance (e.g., production flow monitoring), improving well operating envelopes through identification of drawdown levels (e.g., gas, water, etc.), facilitating targeted remedial action for efficient well management and well integrity, reducing operational risk through the clear identification of anomalies and/or failures in well barrier elements. In some embodiments, use of the systems and methods described herein may provide knowledge of the zones contributing to fluid inflow and their relative concentrations, thereby potentially allowing for improved remediation actions based on the processing results. The methods and systems disclosed herein can also provide information on the variability of the amount of fluid inflow being produced by the different fluid influx zones as a function of different production rates, different production chokes, and downhole pressure conditions, thereby enabling control of fluid inflow. Embodiments of the systems and methods disclosed herein also allow for a computation of the relative concentrations of fluid ingress (e.g., relative amounts of gas, hydrocarbon liquid, and water in the inflow fluid) into the wellbore, thereby offering the potential for more targeted and effective remediation. As disclosed herein, embodiments of the data processing techniques use a sequence of real time digital signal processing steps to identify the acoustic signal resulting from fluid inflow from background noise, and allow real time detection of downhole fluid inflow zones using distributed fiber optic acoustic sensor data as the input data feed. As disclosed herein, a model can be developed using test data to identify one or more signatures based on features of the test data and one or more machine learning techniques to develop correlations for the presence of various flow and/or inflow regimes using the signatures. In the inflow model development, specific flow regimes can be introduced into a test set-up and the acoustic signals obtained and recorded to develop test data. The test data can be used to train one or more models defining the various flow and inflow regimes. The resulting model can then be used to determine one or more inflow and/or flow regimes within the wellbore. Use of the models are described initially, and the process and systems for developing the models used to identify the flow regimes are described in more detail herein. Referring now toFIG.1, a flow chart of a method I of identifying fluid flow and/or inflow according to some embodiments of this disclosure is shown. As described herein, the methods and systems can be used to identify fluid flow. As used herein fluid flow can comprise fluid flow along or within a tubular within the wellbore such as fluid flow within a production tubular. Fluid flow can also comprise fluid flow from the reservoir or formation into a wellbore tubular. Such flow into the wellbore and/or a wellbore tubular can be referred to as fluid inflow. While fluid inflow may be separately identified at times in this disclosure, such fluid inflow is considered a part of fluid flow within the wellbore. A method of identifying fluid flow and/or inflow can comprise obtaining an acoustic signal along the wellbore at100and determining one or a plurality of frequency domain features from the acoustic signal at300. In some embodiments, the method includes identifying one or more fluid inflow locations at500. In some embodiments, the method includes determining fluid inflow discrimination, and the method can also include identifying at least one of a gas phase inflow, an aqueous phase inflow, or a hydrocarbon liquid phase inflow at one or more fluid inflow locations using the plurality of frequency domain features at600. When used to identify flow regimes, the method can include identifying at least one of a gas phase flow, an aqueous phase flow, and/or a hydrocarbon liquid phase flow at one or more locations in the wellbore. As depicted in the embodiment ofFIG.1, a method of identifying fluid flow and/or inflow according to this disclosure can include preprocessing the acoustic signal at200prior to determining the one or the plurality of frequency domain features from the acoustic signal at300, normalizing the one or the plurality of frequency domain features at400, prior to identifying the one or more fluid flow locations at500and/or identifying the at least one of the gas phase flow, an aqueous phase flow, and/or a hydrocarbon liquid phase flow at one or more fluid flow locations, including in some embodiments inflow locations, using the plurality of frequency domain features at600. As further depicted in the embodiment ofFIG.1, identifying the at least one of the gas phase flow, the aqueous phase flow, or the hydrocarbon liquid phase flow at the one or more fluid flow locations (e.g., along a tubular, inflow locations, etc.) using the plurality of frequency domain features at600can comprise providing the plurality of frequency domain features to a fluid flow model as indicated at600′, where the model is described in more detail herein. A method of identifying fluid inflow according to this disclosure can further comprise, at650, determining a confidence level for the identifying of the at least one of the gas phase flow, the aqueous phase flow, or the hydrocarbon liquid phase flow at the one or more fluid flow locations using the plurality of frequency domain features at600and/or determining a relative amounts of the gas phase flow, the aqueous phase flow, and the hydrocarbon phase flow at700prior to determining at800a remediation procedure based on the relative amounts of the gas phase flow, the aqueous phase flow, and the hydrocarbon phase flow determined at700and/or the confidence level determined at650. Each of the aforementioned steps of method I will be described in more detail hereinbelow. A method of identifying fluid inflow and/or fluid flow according to some embodiments of this disclosure comprises obtaining an acoustic signal at100. Such an acoustic signal can be obtained via any methods known to those of skill in the art. An exemplary system and method for obtaining the acoustic signal will now be described with reference toFIG.2, which is a schematic, cross-sectional illustration of a downhole wellbore operating environment101according to an embodiment of this disclosure. As will be described in more detail below, embodiments of completion assemblies comprising a distributed acoustic sensor (DAS) system as described herein can be positioned in environment101. As shown inFIG.2, exemplary environment101includes a wellbore114traversing a subterranean formation102, casing112lining at least a portion of wellbore114, and a tubular120extending through wellbore114and casing112. A plurality of completion assemblies such as spaced screen elements or assemblies118can be provided along tubular120. In addition, a plurality of spaced zonal isolation device117and gravel packs122may be provided between tubular120and the sidewall of wellbore114. In some embodiments, the operating environment101includes a workover and/or drilling rig positioned at the surface and extending over the wellbore114. While shown with an exemplary completion configuration inFIG.2, other equipment may be present in place of or in addition to the equipment illustrated inFIG.2. In general, the wellbore114can be drilled into the subterranean formation102using any suitable drilling technique. The wellbore114can extend substantially vertically from the earth's surface over a vertical wellbore portion, deviate from vertical relative to the earth's surface over a deviated wellbore portion, and/or transition to a horizontal wellbore portion. In general, all or portions of a wellbore may be vertical, deviated at any suitable angle, horizontal, and/or curved. In addition, the wellbore114can be a new wellbore, an existing wellbore, a straight wellbore, an extended reach wellbore, a sidetracked wellbore, a multi-lateral wellbore, and other types of wellbores for drilling and completing one or more production zones. As illustrated, the wellbore114includes a substantially vertical producing section150, which is an open hole completion (i.e., casing112does not extend through producing section150). Although section150is illustrated as a vertical and open hole portion of wellbore114inFIG.1, embodiments disclosed herein can be employed in sections of wellbores having any orientation, and in open or cased sections of wellbores. The casing112extends into the wellbore114from the surface and can be cemented within the wellbore114with cement111. The tubular120can be lowered into the wellbore114for performing an operation such as drilling, completion, intervention, workover, treatment, and/or production processes. In the embodiment shown inFIG.2, the tubular120is a completion assembly string including a distributed acoustic sensor (DAS) sensor coupled thereto. However, in general, embodiments of the tubular120can function as a different type of structure in a wellbore including, without limitation, as a drill string, casing, liner, jointed tubing, and/or coiled tubing. Further, the tubular120may operate in any portion of the wellbore114(e.g., vertical, deviated, horizontal, and/or curved section of wellbore114). Embodiments of DAS systems described herein can be coupled to the exterior of the tubular120, or in some embodiments, disposed within an interior of the tubular120, as shown inFIGS.3A and3B, respectively. When the DAS fiber is coupled to the exterior of the tubular120, as depicted in the embodiment ofFIG.3B, the DAS fiber can be positioned within a control line, control channel, or recess in the tubular120. In some embodiments an outer shroud contains the tubular120and protects the system during installation. A control line or channel can be formed in the shroud and the DAS fiber can be placed in the control line or channel. The tubular120can extend from the surface to the producing zones and generally provides a conduit for fluids to travel from the formation102to the surface. A completion assembly including the tubular120can include a variety of other equipment or downhole tools to facilitate the production of the formation fluids from the production zones. For example, zonal isolation devices117can be used to isolate the various zones within the wellbore114. In this embodiment, each zonal isolation device117can be a packer (e.g., production packer, gravel pack packer, frac-pac packer, etc.). The zonal isolation devices117can be positioned between the screen assemblies118, for example, to isolate different gravel pack zones or intervals along the wellbore114from each other. In general, the space between each pair of adjacent zonal isolation devices117defines a production interval. The screen assemblies118provide sand control capability. In particular, the sand control screen elements118, or other filter media associated with wellbore tubular120, can be designed to allow fluids to flow therethrough but restrict and/or prevent particulate matter of sufficient size from flowing therethrough. The screen assemblies118can be of the type known as “wire-wrapped”, which are made up of a wire closely wrapped helically about a wellbore tubular, with a spacing between the wire wraps being chosen to allow fluid flow through the filter media while keeping particulates that are greater than a selected size from passing between the wire wraps. Other types of filter media can also be provided along the tubular120and can include any type of structures commonly used in gravel pack well completions, which permit the flow of fluids through the filter or screen while restricting and/or blocking the flow of particulates (e.g. other commercially-available screens, slotted or perforated liners or pipes; sintered-metal screens; sintered-sized, mesh screens; screened pipes; prepacked screens and/or liners; or combinations thereof). A protective outer shroud having a plurality of perforations therethrough may be positioned around the exterior of any such filter medium. The gravel packs122are formed in the annulus119between the screen elements118(or tubular120) and the sidewall of the wellbore114in an open hole completion. In general, the gravel packs122comprise relatively coarse granular material placed in the annulus to form a rough screen against the ingress of sand into the wellbore while also supporting the wellbore wall. The gravel pack122is optional and may not be present in all completions. The fluid flowing into the tubular120may comprise more than one fluid component. Typical components include natural gas, oil (e.g., hydrocarbon liquids), water, steam, carbon dioxide, and/or various multiphase mixed flows. The fluid flow can further be time varying such as including slugging, bubbling, or time altering flow rates of different phases. The relative proportions of these components can vary over time based on conditions within the formation102and the wellbore114. Likewise, the composition of the fluid flowing into the tubular120sections throughout the length of the entire production string can vary significantly from section to section at any given time. Fluid can be produced into the wellbore114and into the completion assembly string. As the fluid enters the wellbore114, it may create acoustic sounds that can be detected using an acoustic sensor such as a DAS system. Accordingly, the flow of the various fluids into the wellbore114and/or through the wellbore114can create vibrations or acoustic sounds that can be detected using sensors to detect the vibrations or acoustic sounds. For example, the vibrations can be detected using a DAS system, though other point types vibration or acoustic sensors can be used alone or in combination with the DAS system. Each type of event such as the different fluid flows and fluid flow locations can produce an acoustic signature with unique frequency domain features. InFIG.2, the DAS comprises an optical fiber162based acoustic sensing system that uses the optical backscatter component of light injected into the optical fiber for detecting acoustic perturbations (e.g., dynamic strain) along the length of the fiber162. The light can be generated by a light generator or source166such as a laser, which can generate light pulses. The optical fiber162acts as the sensor element with no addition transducers in the optical path, and measurements can be taken along the length of the entire optical fiber162. The measurements can then be detected by an optical receiver such as sensor164and selectively filtered to obtain measurements from a given depth point or range, thereby providing for a distributed measurement that has selective data for a plurality of zones along the optical fiber162at any given time. In this manner, the optical fiber162effectively functions as a distributed array of microphones spread over the entire length of the optical fiber162, which typically spans at least the production zone150of the wellbore114, to detect downhole acoustics. The light backscattered up the optical fiber162as a result of the optical backscatter can travel back to the source, where the signal can be collected by a sensor164and processed (e.g., using a processor168). In general, the time the light takes to return to the collection point is proportional to the distance traveled along the optical fiber162. The resulting backscattered light arising along the length of the optical fiber162can be used to characterize the environment around the optical fiber162. The use of a controlled light source166(e.g., having a controlled spectral width and frequency) may allow the backscatter to be collected and any disturbances along the length of the optical fiber162to be analyzed. In general, any acoustic or dynamic strain disturbances along the length of the optical fiber162can result in a change in the properties of the backscattered light, allowing for a distributed measurement of both the acoustic magnitude (e.g., amplitude), frequency and, in some cases, of the relative phase of the disturbance. An acquisition device160can be coupled to one end of the optical fiber162. As discussed herein, the light source166can generate the light (e.g., one or more light pulses), and the sensor164can collect and analyze the backscattered light returning up the optical fiber162. In some contexts, the acquisition device160including the light source166and the sensor164can be referred to as an interrogator. In addition to the light source166and the sensor164, the acquisition device160generally comprises a processor168in signal communication with the sensor164to perform various analysis steps described in more detail herein. While shown as being within the acquisition device160, the processor can also be located outside of the acquisition device160including being located remotely from the acquisition device160. The sensor164can be used to obtain data at various rates and may obtain data at a sufficient rate to detect the acoustic signals of interest with sufficient bandwidth. In an embodiment, depth resolution ranges in a range of from about 1 meter to about 10 meters, or less than or equal to about 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 meter can be achieved. Depending on the resolution needs, larger averages or ranges can be used for computing purposes. When a high depth resolution is not needed, a system having a wider resolution (e.g., which may be less expensive) can also be used in some embodiments. While the system101described herein can be used with a DAS system to acquire an acoustic signal for a location or depth range in the wellbore114, in general, any suitable acoustic signal acquisition system can be used with the method steps disclosed herein. For example, various microphones or other sensors can be used to provide an acoustic signal at a given location based on the acoustic signal processing described herein. A benefit of the use of the DAS system is that an acoustic signal can be obtained across a plurality of locations and/or across a continuous length of the wellbore114rather than at discrete locations. Specific spectral signatures can be determined for each event by considering one or more frequency domain features of the acoustic signal obtained from the wellbore. The resulting spectral signatures can then be used along with processed acoustic signal data to determine if an event is occurring at a depth range of interest. The events can include various fluid flows and/or inflows as described herein. The spectral signatures can be determined by considering the different types of flow occurring within a wellbore and characterizing the frequency domain features for each type of flow. In some embodiments, various combinations and/or transformations of the frequency domain features can be used to characterize each type of flow. FIG.4schematically illustrates an exemplary view of an embodiment of a wellbore tubular120with fluid inflow including a gas phase (e.g., as depicted as gas bubbles202) with or without a liquid phase, and shown in the cross-sectional illustrations inFIGS.3A and3B, fluid (e.g., gas, hydrocarbon liquid, water). The gas phase depicted as202can flow from the formation102into the wellbore114and then into the tubular120. As the fluid202flows into the tubular120, various acoustic signals can be generated, and as the fluid202flows within the tubular120, additional acoustic signals, which can be the same or different than the inflow signals, can also be generated. The acoustic signals can then be detected by the DAS fiber and recorded using the DAS system. Without being limited by this or any particular theory, the spectral characteristics of the sounds generated by each type of fluid flow and/or inflow can depend on the effective mass and flow rate of each fluid. In some embodiments, the acoustic signals obtained at100can include frequencies in the range of about 5 Hz to about 10 kHz, frequencies in the range of about 5 Hz to about 5 kHz or about 50 Hz to about 5 kHz, or frequencies in the range of about 500 Hz to about 5 kHz. Any frequency ranges between the lower frequency values (e.g., 5 Hz, 50 Hz, 500 Hz, etc.) and the upper frequency values (e.g., 10 kHz, 7 kHz, 5 kHz, etc.) can be used to define the frequency range for a broadband acoustic signal. Taking gas flow and/or inflow as an example, the proximity to the optical fiber162can result in a high likelihood that any acoustic signals generated would be detected by the optical fiber162. The flow of a gas into the wellbore would likely result in a turbulent flow over a broad frequency range. For example, the gas inflow acoustic signals can be between about 0 Hz and about 1000 Hz, or alternatively between about 0 Hz and about 500 Hz. An increased power intensity may occur between about 300 Hz and about 500 Hz from increased turbulence in the gas flow. An example of the acoustic signal resulting from the influx of gas into the wellbore is shown inFIG.5, which illustrates frequency filtered acoustic intensity in depth versus time graphs for five frequency bins. As illustrated, the five frequency bins represent 5 Hz to 50 Hz, 50 Hz to 100 Hz, 100 Hz to 500 Hz, 500 Hz to 2000 Hz, and 2000 Hz to 5000 Hz. The acoustic intensity can be seen in the first three bins with frequency ranges up to about 500 Hz, with a nearly undetectable acoustic intensity in the frequency range above 500 Hz. This demonstrates that at least a portion of the frequency domain features may not be present above 500 Hz, which can help to define the signature of the influx of gas. This type of response demonstrates that each event can be expected to produce an acoustic response having potentially unique feature sets that can be used to help define a signature for the event. While described in terms of frequency ranges or bins, other features and transformations of such features can be used to help define the gas flow and/or inflow signatures, which can be used with a multivariate model for determining if gas flow and/or inflow is present. Similar frequency features can be expected for other fluid inflows as well as fluid flows along a tubular within the wellbore. The resulting acoustic signal can be processed to determine a plurality of frequency domain features. The signatures for each type of fluid flow can then be based on a plurality of frequency domain features. This can include transforming one or more of the frequency domain features to serve as an element of a specific fluid flow signature, as described in more detail herein. Referring again toFIG.2, the processor168within the acquisition device160can be configured to perform various data processing to detect the presence of fluid inflow along the length of the wellbore114. The acquisition device160can comprise a memory170configured to store an application or program to perform the data analysis. While shown as being contained within the acquisition device160, the memory170can comprise one or more memories, any of which can be external to the acquisition device160. In an embodiment, the processor168can execute the program, which can configure the processor168to filter the acoustic data set spatially, determine one or more frequency domain features of the acoustic signal, and determine whether or not fluid inflow is occurring at the selected location based on the analysis described hereinbelow, and whether any fluid inflow comprises water inflow, hydrocarbon liquid inflow, and gas inflow. The analysis can be repeated across various locations along the length of the wellbore114to determine the locations of fluid inflow and/or the type of fluid (e.g., gas, water, hydrocarbon liquid) inflowing along the length of the wellbore114. When the acoustic sensor comprises a DAS system, the optical fiber162can return raw optical data in real time or near real time to the acquisition unit160. In an embodiment, the raw data can be stored in the memory170for various subsequent uses. The sensor164can be configured to convert the raw optical data into an acoustic data set. As shown schematically inFIG.6, an embodiment of a system401for detecting fluid and/or fluid phase of an inflow can comprise a data extraction unit402, a processing unit404, and/or an output or visualization unit406. The data extraction unit402can obtain the optical data and perform the initial pre-processing steps to obtain the initial acoustic information from the signal returned from the wellbore. Various analyses can be performed including frequency band extraction, frequency analysis and/or transformation, intensity and/or energy calculations, and/or determination of one or more properties of the acoustic data. Following the data extraction unit402, the resulting signals can be sent to a processing unit404. Within the processing unit, the acoustic data can be analyzed, for example, by calculating one or more frequency domain features and utilizing a model or models obtained from a machine learning approach (e.g., a supervised learning approach, etc.) on the one or more frequency domain features as described further hereinbelow to determine if fluid flow and/or inflow is present, and, if present, determining if the fluid flow and/or inflow comprises water flow and/or inflow, hydrocarbon liquid flow and/or inflow, and/or gas flow and/or inflow. One or more models can also be used to determine the presence of various fluid flow regimes within a conduit within the wellbore. In some embodiments, the machine learning approach comprises a logistic regression model. In some such embodiments, a single frequency domain feature (e.g., spectral flatness, RMS bin values, etc.) can be used to determine if fluid inflow is present at each location of interest. In some embodiments, the supervised learning approach can be used to determine a model of the various flow regimes such as a first polynomial having the plurality of frequency domain features as inputs to determine when gas phase inflow is present, a second polynomial having the plurality of frequency domain features as inputs to determine when aqueous phase inflow is present, and a third polynomial having the plurality of frequency domain features as inputs to determine when hydrocarbon liquid phase inflow is present. Once the processing unit404uses the model obtained from the machine learning approach to determine the presence or lack of fluid inflow (e.g., gas inflow, water inflow, hydrocarbon liquid inflow, etc.) and the composition thereof (e.g., gas, hydrocarbon liquid, water), the resulting analysis information can then be sent from the processing unit404to the output/visualization unit406where various information such a visualization of the location of the inflow and/or information providing quantification information (e.g., a relative amount of gas inflow, water inflow, hydrocarbon liquid inflow, and the like) can be visualized in a number of ways. In an embodiment, the resulting event information can be visualized on a well schematic, on a time log, or any other number of displays to aid in understanding where the inflow is occurring, and in some embodiments, to display a relative amount of the various components of the inflowing fluid occurring at one or more locations along the length of the wellbore. While illustrated inFIG.6as separate units, any two or more of the units shown inFIG.6can be incorporated into a single unit. For example, a single unit can be present at the wellsite to provide analysis, output, and optionally, visualization of the resulting information. As noted above, a method of identifying fluid flow according to this disclosure can comprise preprocessing the acoustic signal. The acoustic signal can be generated within the wellbore as described herein. Depending on the type of DAS system employed, the optical data may or may not be phase coherent and may be pre-processed to improve the signal quality (e.g., denoised for opto-electronic noise normalization/de-trending single point-reflection noise removal through the use of median filtering techniques or even through the use of spatial moving average computations with averaging windows set to the spatial resolution of the acquisition unit, etc.). The raw optical data from the acoustic sensor can be received and generated by the sensor to produce the acoustic signal. The data rate generated by various acoustic sensors such as the DAS system can be large. For example, the DAS system may generate data on the order of 0.5 to about 2 terabytes per hour. This raw data can optionally be stored in a memory. The raw data can then be optionally pre-processed in step200. A number of specific processing steps can be performed to determine the presence of fluid inflow and/or the composition of inflowing fluid. In an embodiment, the noise detrended “acoustic variant” data can be subjected to an optional spatial filtering step following the other pre-processing steps, if present. A spatial sample point filter can be applied that uses a filter to obtain a portion of the acoustic signal corresponding to a desired depth in the wellbore. Since the time the light pulse sent into the optical fiber returns as backscattered light can correspond to the travel distance, and therefore depth in the wellbore, the acoustic data can be processed to obtain a sample indicative of the desired depth or depth range. This may allow a specific location within the wellbore to be isolated for further analysis. The pre-processing step may also include removal of spurious back reflection type noises at specific depths through spatial median filtering or spatial averaging techniques. This is an optional step and helps focus primarily on an interval of interest in the wellbore. For example, the spatial filtering step can be used to focus on a producing interval where there is maximum likelihood of fluid inflow, for example. The resulting data set produced through the conversion of the raw optical data can be referred to as the acoustic sample data. Filtering can provide several advantages. When the acoustic data set is spatially filtered, the resulting data, for example the acoustic sample data, used for the next step of the analysis can be indicative of an acoustic sample over a defined depth (e.g., the entire length of the optical fiber, some portion thereof, or a point source in the wellbore114). In some embodiments, the acoustic data set can comprise a plurality of acoustic samples resulting from the spatial filter to provide data over a number of depth ranges. In some embodiments, the acoustic sample may contain acoustic data over a depth range sufficient to capture multiple points of interest. In some embodiments, the acoustic sample data contains information over the entire frequency range at the depth represented by the sample. This is to say that the various filtering steps, including the spatial filtering, do not remove the frequency information from the acoustic sample data. The processor168can be further configured to transform the filtered data from the time domain into the frequency domain using a transform. For example, Discrete Fourier transformations (DFT) or a short time Fourier transform (STFT) of the acoustic variant time domain data measured at each depth section along the fiber or a section thereof may be performed to provide the data from which the plurality of frequency domain features can be determined. Spectral feature extraction through time and space can be used to determine the spectral conformance and determine if an acoustic signature (e.g., a fluid inflow signature, a gas phase inflow signature, a water phase inflow signature, a hydrocarbon liquid phase inflow signature, etc.) is present in the acoustic sample. Within this process, various frequency domain features can be calculated for the acoustic sample data. Preprocessing at200can optionally include a noise normalization routine to improve the signal quality. This step can vary depending on the type of acquisition device used as well as the configuration of the light source, the sensor, and the other processing routines. The order of the aforementioned preprocessing steps can be varied, and any order of the steps can be used. Preprocessing at200can further comprise calibrating the acoustic signal. Calibrating the acoustic signal can comprise removing a background signal from the acoustic signal, and/or correcting the acoustic signal for signal variations in the measured data. In some embodiments, calibrating the acoustic signal comprises identifying one or more anomalies within the acoustic signal and removing one or more portions of the acoustic signal outside the one or more anomalies. As noted hereinabove, a method of this disclosure comprises determining one or more frequency domain features or indicators at step300. The use of frequency domain features to identify inflow locations and inflow discrimination can provide a number of advantages. First, the use of frequency domain features results in significant data reduction relative to the raw DAS data stream. Thus, a number of frequency domain features can be calculated and used to allow for event identification while the remaining data can be discarded or otherwise stored, and the remaining analysis can be performed using the frequency domain features. Even when the raw DAS data is stored, the remaining processing power is significantly reduced through the use of the frequency domain features rather than the raw acoustic data itself. Further, the use of the frequency domain features can, with the appropriate selection of one or more of the frequency domain features, provide a concise, quantitative measure of the spectral character or acoustic signature of specific sounds pertinent to downhole fluid surveillance and other applications. While a number of frequency domain features can be determined for the acoustic sample data, not every frequency domain feature may be used in the identifying fluid flow characteristics, the locations of fluid inflow, or identifying at least one of a gas phase inflow, an aqueous phase inflow, or a hydrocarbon liquid phase inflow. The frequency domain features represent specific properties or characteristics of the acoustic signals. There are a number of factors that can affect the frequency domain feature selection for each fluid inflow event. For example, a chosen descriptor should remain relatively unaffected by the interfering influences from the environment such as interfering noise from the electronics/optics, concurrent acoustic sounds, distortions in the transmission channel, and the like. In general, electronic/instrumentation noise is present in the acoustic signals captured on the DAS or any other electronic gauge, and it is usually an unwanted component that interferes with the signal. Thermal noise is introduced during capturing and processing of signals by analogue devices that form a part of the instrumentation (e.g., electronic amplifiers and other analog circuitry). This is primarily due to thermal motion of charge carriers. In digital systems additional noise may be introduced through sampling and quantization. The frequency domain features should have values that are significant for a given even in the presence of noise. As a further consideration in selecting the frequency domain feature(s) for a fluid inflow event, the dimensionality of the frequency domain feature should be compact. A compact representation is desired to decrease the computational complexity of subsequent calculations. The frequency domain feature should also have discriminant power. For example, for different types of audio signals, the selected set of descriptors should provide altogether different values. A measure for the discriminant power of a feature is the variance of the resulting feature vectors for a set of relevant input signals. Given different classes of similar signals, a discriminatory descriptor should have low variance inside each class and high variance over different classes. The frequency domain feature should also be able to completely cover the range of values of the property it describes. In some embodiments, combinations of frequency domain features can be used. This can include a signature having multiple frequency domain features as indicators. In some embodiments, a plurality of frequency domain features can be transformed to create values that can be used to define various event signatures. This can include mathematical transformations including ratios, equations, rates of change, transforms (e.g., wavelets, Fourier transforms, other wave form transforms, etc.), other features derived from the feature set, and/or the like as well as the use of various equations that can define lines, surfaces, volumes, or multi-variable envelopes. The transformation can use other measurements or values outside of the frequency domain features as part of the transformation. For example, time domain features, other acoustic features, and non-acoustic measurements can also be used. In this type of analysis, time can also be considered as a factor in addition to the frequency domain features themselves. As an example, a plurality of frequency domain features can be used to define a surface (e.g., a plane, a three-dimensional surface, etc.) in a multivariable space, and the measured frequency domain features can then be used to determine if the specific readings from an acoustic sample fall above or below the surface. The positioning of the readings relative to the surface can then be used to determine if the event if present or not at that location in that detected acoustic sample. As an example, the chosen set of frequency domain features should be able to uniquely identify the event signatures with a reasonable degree of certainty of each of the acoustic signals pertaining to a selected downhole surveillance application or fluid inflow event as described herein. Such frequency domain features can include, but are not limited to, the spectral centroid, the spectral spread, the spectral roll-off, the spectral skewness, the root mean square (RMS) band energy (or the normalized subband energies/band energy ratios), a loudness or total RMS energy, a spectral flatness, a spectral slope, a spectral kurtosis, a spectral flux, a spectral autocorrelation function, or a normalized variant thereof. The spectral centroid denotes the “brightness” of the sound captured by the optical fiber162and indicates the center of gravity of the frequency spectrum in the acoustic sample. The spectral centroid can be calculated as the weighted mean of the frequencies present in the signal, where the magnitudes of the frequencies present can be used as their weights in some embodiments. The value of the spectral centroid, Ci, of the ithframe of the acoustic signal captured at a spatial location on the fiber, may be written as: Ci=∑k=1Nf(k)Xi(k)∑k=1NXi(k),(Eq.1) where Xi(k), is the magnitude of the short time Fourier transform of the ithframe where ‘k’ denotes the frequency coefficient or bin index, N denotes the total number of bins and f(k) denotes the centre frequency of the bin. The computed spectral centroid may be scaled to value between 0 and 1. Higher spectral centroids typically indicate the presence of higher frequency acoustics and help provide an immediate indication of the presence of high frequency noise. The spectral spread can also be determined for the acoustic sample. The spectral spread is a measure of the shape of the spectrum and helps measure how the spectrum is distributed around the spectral centroid. In order to compute the spectral spread, Si, one has to take the deviation of the spectrum from the computed centroid as per the following equation (all other terms defined above): Si=∑k=1N(f(k)-Ci)2Xi(k)∑k=1NXi(k).(Eq.2) Lower values of the spectral spread correspond to signals whose spectra are tightly concentrated around the spectral centroid. Higher values represent a wider spread of the spectral magnitudes and provide an indication of the presence of a broad band spectral response. The spectral roll-off is a measure of the bandwidth of the audio signal. The Spectral roll-off of the ithframe, is defined as the frequency bin ‘y’ below which the accumulated magnitudes of the short-time Fourier transform reach a certain percentage value (usually between 85%-95%) of the overall sum of magnitudes of the spectrum. ∑k=1yXi(k)=c100∑k=1NXi(k),(Eq.3) where c=85 or 95. The result of the spectral roll-off calculation is a bin index and enables distinguishing acoustic events based on dominant energy contributions in the frequency domain. (e.g., between gas influx and liquid flow, etc.) The spectral skewness measures the symmetry of the distribution of the spectral magnitude values around their arithmetic mean. The RMS band energy provides a measure of the signal energy within defined frequency bins that may then be used for signal amplitude population. The selection of the bandwidths can be based on the characteristics of the captured acoustic signal. In some embodiments, a sub-band energy ratio representing the ratio of the upper frequency in the selected band to the lower frequency in the selected band can range between about 1.5:1 to about 3:1. In some embodiments, the subband energy ratio can range from about 2.5:1 to about 1.8:1, or alternatively be about 2:1. In some embodiment, selected frequency ranges for a signal with a 5,000 Hz Nyquist acquisition bandwidth can include: a first bin with a frequency range between 0 Hz and 20 Hz, a second bin with a frequency range between 20 Hz and 40 Hz, a third bin with a frequency range between 40 Hz and 80 Hz, a fourth bin with a frequency range between 80 Hz and 160 Hz, a fifth bin with a frequency range between 160 Hz and 320 Hz, a sixth bin with a frequency range between 320 Hz and 640 Hz, a seventh bin with a frequency range between 640 Hz and 1280 Hz, an eighth bin with a frequency range between 1280 Hz and 2500 Hz, and a ninth bin with a frequency range between 2500 Hz and 5000 Hz. In some embodiments, a low frequency threshold can be used to help to reduce noise in the signal. For example, a lower frequency threshold between 0 and 5 Hz, between 0 and 10 Hz, or between 0 and 15 Hz can be used, which can result in the first bin including a frequency range between 5 Hz and 20 Hz, between 10 Hz and 20 Hz, or between 15 Hz and 20 Hz depending on the lower frequency threshold used. In some embodiments, a ninth bin can be defined as cover the entire frequency range covered by the other bins. For example, a ninth bin can have a frequency range from 0 Hz to 5,000 Hz (or between 5 Hz and 5,000 Hz, 10 Hz and 5,000 Hz, or 15 Hz and 5,000 Hz, depending on whether or not a lower threshold is used and the choice of that threshold). The bin covering the entire frequency range can be used, in some embodiments, to normalize the measurements within each individual bin. While certain frequency ranges for each bin are listed herein, they are used as examples only, and other values in the same or a different number of frequency range bins can also be used. In some embodiments, the RMS band energies may also be expressed as a ratiometric measure by computing the ratio of the RMS signal energy within the defined frequency bins relative to the total RMS energy across the acquisition (Nyquist) bandwidth. This may help to reduce or remove the dependencies on the noise and any momentary variations in the broadband sound. The total RMS energy of the acoustic waveform calculated in the time domain can indicate the loudness of the acoustic signal. In some embodiments, the total RMS energy can also be extracted from the temporal domain after filtering the signal for noise. The spectral flatness is a measure of the noisiness/tonality of an acoustic spectrum. It can be computed by the ratio of the geometric mean to the arithmetic mean of the energy spectrum value and may be used as an alternative approach to detect broadbanded signals. For tonal signals, the spectral flatness can be close to 0 and for broader band signals it can be closer to 1. The spectral slope provides a basic approximation of the spectrum shape by a linearly regressed line. The spectral slope represents the decrease of the spectral amplitudes from low to high frequencies (e.g., a spectral tilt). The slope, the y-intersection, and the max and media regression error may be used as features. The spectral kurtosis provides a measure of the flatness of a distribution around the mean value. The spectral flux is a measure of instantaneous changes in the magnitude of a spectrum. It provides a measure of the frame-to-frame squared difference of the spectral magnitude vector summed across all frequencies or a selected portion of the spectrum. Signals with slowly varying (or nearly constant) spectral properties (e.g., noise) have a low spectral flux, while signals with abrupt spectral changes have a high spectral flux. The spectral flux can allow for a direct measure of the local spectral rate of change and consequently serves as an event detection scheme that could be used to pick up the onset of acoustic events that may then be further analyzed using the feature set above to identify and uniquely classify the acoustic signal. The spectral autocorrelation function provides a method in which the signal is shifted, and for each signal shift (lag) the correlation or the resemblance of the shifted signal with the original one is computed. This enables computation of the fundamental period by choosing the lag, for which the signal best resembles itself, for example, where the autocorrelation is maximized. This can be useful in exploratory signature analysis/even for anomaly detection for well integrity monitoring across specific depths where well barrier elements to be monitored are positioned. Any of these frequency domain features, or any combination of these frequency domain features (including transformations of any of the frequency domain features and combinations thereof), can be used to identify the location of fluid inflow or the fluid inflow discrimination as described hereinbelow. In an embodiment, a selected set of characteristics can be used to identify the presence or absence for each fluid inflow event, and/or all of the frequency domain features that are calculated can be used as a group in characterizing the presence or absence of a fluid inflow event. The specific values for the frequency domain features that are calculated can vary depending on the specific attributes of the acoustic signal acquisition system, such that the absolute value of each frequency domain feature can change between systems. In some embodiments, the frequency domain features can be calculated for each event based on the system being used to capture the acoustic signal and/or the differences between systems can be taken into account in determining the frequency domain feature values for each fluid inflow event between or among the systems used to determine the values and the systems used to capture the acoustic signal being evaluated. One or a plurality of frequency domain features can be used to characterize each type of event (e.g., fluid inflow, water inflow, gas inflow, hydrocarbon liquid inflow). In an embodiment, one, at least two, alternatively at least three, alternatively at least four, alternatively at least five, alternatively at least six, alternatively at least seven, or alternatively at least eight different frequency domain features can be used to characterize each type of event (e.g., fluid inflow, water inflow, gas inflow, hydrocarbon liquid inflow). The frequency domain features can be combined or transformed in order to define the event signatures for one or more events. While exemplary numerical ranges are provided herein, the actual numerical results may vary depending on the data acquisition system and/or the values can be normalized or otherwise processed to provide different results. As noted above, in order to obtain the frequency domain features, the acoustic sample data can be converted to the frequency domain at preprocessing step200. In an embodiment, the raw optical data may contain or represent acoustic data in the time domain. Thus, in some embodiments, preprocessing at200comprises obtaining a frequency domain representation of the data using a Fourier Transform. Various algorithms can be used as known in the art. In some embodiments, a Short Time Fourier Transform technique or a Discrete Time Fourier transform can be used. The resulting data sample may then be represented by a range of frequencies relative to their power levels at which they are present. The raw optical data can be transformed into the frequency domain prior to or after the application of the spatial filter. In general, the acoustic sample will be in the frequency domain in order to determine the frequency domain feature(s). In some embodiments, the processor168can be configured to perform the conversion of the raw acoustic data and/or the acoustic sample data from the time domain into the frequency domain. In the process of converting the signal to the frequency domain, the power across all frequencies within the acoustic sample can be analyzed. The use of the processor168to perform the transformation may provide the frequency domain data in real time or near real time. The processor168can then be used to analyze the acoustic sample data in the frequency domain to obtain one or more of the frequency domain features and provide an output with the determined frequency domain features for further processing. In some embodiments, the output of the frequency domain features can include features that are not used to determine the presence of fluid inflow, water phase inflow, gas inflow, hydrocarbon liquid inflow. The output of the processor with the frequency domain features for the acoustic sample data can then be used to determine the presence of one or more fluid flow and/or inflow events at one or more locations in the wellbore corresponding to depth intervals over which the acoustic data is acquired or filtered. A method of identifying fluid inflow can optionally comprise normalizing the one or the plurality of frequency domain features at400prior to identifying the one or more fluid inflow locations at500and/or prior to identifying the at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow at600. A method of identifying fluid flow and/or inflow according to this disclosure can comprise identifying one or more fluid flow and/or inflow locations at500. Such fluid inflow locations can be determined as known to those of skill in the art, for example via PLS data. In some embodiments, the one or more fluid inflow locations are determined as described hereinbelow. In such embodiments, identifying one or more fluid flow and/or inflow locations can comprise identifying the one or more fluid flow and/or inflow locations using one or more of the frequency domain features to identify acoustic signals corresponding to the flow and/or inflow, and correlating the depths of those signals with locations within the wellbore. The one or more frequency domain features can comprise at least two different frequency domain features. In some embodiments, the one or more frequency domain features utilized to determine the one or more fluid inflow locations comprises at least one of a spectral centroid, a spectral spread, a spectral roll-off, a spectral skewness, an RMS band energy, a total RMS energy, a spectral flatness, a spectral slope, a spectral kurtosis, a spectral flux, a spectral autocorrelation function, combinations and/or transformations thereof, and/or a normalized variant thereof. In some embodiments, the one or more frequency domain features utilized to determine the one or more fluid inflow locations include a spectral flatness, an RMS band energy, a total RMS energy, or a normalized variant of one or more of the spectral flatness, the RMS band energy, the total RMS energy, or a combination thereof. In some embodiments, identifying the one or more fluid inflow locations comprises: identifying a background fluid flow signature using the acoustic signal; and removing the background fluid flow signature from the acoustic signal prior to identifying the one or more fluid inflow locations. In some embodiments, identifying the one or more fluid inflow locations comprises identifying one or more anomalies in the acoustic signal using the one or more frequency domain features of the plurality of frequency domain features; and selecting the depth intervals of the one or more anomalies as the one or more inflow locations. When a portion of the signal is removed (e.g., a background fluid flow signature, etc.), the removed portion can also be used as part of the event analysis. In some embodiments, identifying the one or more fluid inflow locations comprises: identifying a background fluid flow signature using the acoustic signal; and using the background fluid flow signature from the acoustic signal to identify as event such as one or more fluid flow events. In some embodiments, a method of identifying fluid flow and/or inflow according to this disclosure comprises identifying at least one of a gas phase inflow, an aqueous phase inflow, or a hydrocarbon liquid phase inflow using a plurality of frequency domain features at the identified one or more fluid inflow locations at600. In some embodiments, the plurality of frequency domain features utilized for identifying the at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow at the identified one or more fluid inflow locations comprises at least two of: a spectral centroid, a spectral spread, a spectral roll-off, a spectral skewness, an RMS band energy, a total RMS energy, a spectral flatness, a spectral slope, a spectral kurtosis, a spectral flux, a spectral autocorrelation function, or a normalized variant thereof. In some embodiments, identifying at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow using the plurality of the frequency domain features at600comprises: identifying the at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow using a value representing a transformation of at least one of the plurality of the frequency domain features. In some embodiments, identifying the at least one of the fluid flow, gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow using the plurality of the frequency domain features at600comprises: identifying the at least one of a fluid flow (e.g., a gas phase flow, an aqueous phase flow, and/or a hydrocarbon phase flow), a gas phase inflow, an aqueous phase inflow, a hydrocarbon liquid phase inflow, or any combination thereof using a multivariate model (e.g., one or more polynomial equations, mathematical formulas, etc.) that defines a relationship between at least two of the plurality of the frequency domain features, including in some embodiments transformations of the frequency domain features. In some embodiments, identifying the at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow using the plurality of the frequency domain features at600comprises: identifying the presence or absence of a gas phase using a first multivariate model having a first at least two of the plurality of frequency domain features as inputs to determine when the gas phase inflow is present, identifying the presence or absence of aqueous phase inflow using a second multivariate model having a second at least two of the plurality of frequency domain features as inputs to determine when the aqueous phase inflow is present, and identifying the presence or absence of an aqueous phase inflow using a third polynomial having a third at least two of the plurality of frequency domain features as inputs to determine when the hydrocarbon liquid phase inflow is present. The first at least two, the second at least two, and the third at least two of the plurality of frequency domain features can be the same or different. In some embodiments, identifying at least one of the fluid flow, gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow using the plurality of the frequency domain features at600comprises: identifying at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow using a ratio between at least two of the plurality of the frequency domain features. In some embodiments, identifying at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow comprises providing the plurality of frequency domain features to a fluid flow and/or inflow (e.g., a logistic regression) model at600′ for each of the gas phase, the aqueous phase, and the hydrocarbon liquid phase; and determining that at least one of the gas phase, the aqueous phase, or the hydrocarbon liquid phase is present based on the fluid flow model. In some embodiments, the fluid flow model can be developed using and/or include machine learning such as a neural network, a Bayesian network, a decision tree, a logistical regression model, or a normalized logistical regression, or other supervised learning models. In some embodiments, the fluid flow and/or inflow model can use a first multivariate model having at least two of the plurality of frequency domain features as inputs to determine when the gas phase inflow is present. The logistic regression model can use a second multivariate model having a second at least two of the plurality of frequency domain features as inputs to determine when the aqueous phase inflow is present, and the logistic regression model can use a third multivariate model having a third at least two of the plurality of frequency domain features as inputs to determine when the hydrocarbon liquid phase inflow is present. The first at least two, the second at least two, and the third at least two of the frequency domain features can be the same or different. The use of different models for one or more types of fluid inflow events can allow for a more accurate determination of each event. The models can differ in a number of ways. For example, the models can have different parameters, different mathematical determinations, be different types of models, and/or use different frequency domain features. In some embodiments, a plurality of models can be used for different fluid inflow events, and at least one of the models can have different parameters. In general, parameters refer to constants or values used within the models to determine the output of the model. In multivariate models as an example, the parameters can be coefficients of one or more terms in the equations in the models. In neural network models as an example, the parameters can be the weightings applied to one or more nodes. Other constants, offsets, and coefficients in various types of models can also represent parameters. The use of different parameters can provide a different output amongst the models when the models are used to identify different types of fluid inflow events. The models can also differ in their mathematical determinations. In multivariate models, the models can comprise one or more terms that can represent linear, non-linear, power, or other functions of the input variables (e.g., one or more frequency domain features, etc.). The functions can then change between the models. As another example, a neural network may have different numbers of layers and nodes, thereby creating a different network used with the input variables. Thus, even when the same frequency domain features are used in two more models, the outputs can vary based on the different functions and/or structures of the models. The models can also be different on the basis of being different types of models. For example, the plurality of models can use regression models to identify one or more fluid inflow events and neural networks for different fluid inflow events. Other types of models are also possible and can be used to identify different types of inflow events. Similarly, the models can be different by using different input variables. The use of different variables can provide different outputs between the models. The use of different models can allow for the same or different training data to be used to produce more accurate results for different types of fluid inflow events. Any of the models described herein can rely on the use of different models for different types of fluid inflow events (e.g., a gas phase inflow, an aqueous phase inflow, a hydrocarbon liquid phase inflow, etc.), as described in more detail herein. In some embodiments, identifying at least one of the fluid flow, the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase comprises utilizing a fluid flow model and using the plurality of frequency domain features at the identified one or more fluid inflow locations in the first multivariate model; using the plurality of frequency domain features at the identified one or more fluid inflow locations in the second multivariate model; using the plurality of frequency domain features at the identified one or more fluid inflow locations in the third multivariate model; comparing the plurality of frequency domain features to an output of the first multivariate model, an output of the second multivariate model, and an output of the third multivariate model; and identifying at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow based on the comparison of the plurality of frequency domain features to the output of the first multivariate model, the output of the second multivariate model, and the output of the third multivariate model. In some embodiments, the plurality of frequency domain features utilized to identify the fluid flow, at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow can include a normalized variant of the spectral spread and/or a normalized variant of the spectral centroid, and the fluid inflow (e.g., logistic regression) model can define a relationship between a presence or absence of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow at the location of the acoustic signal. In addition to the multivariate model(s) used to determine the presence and identity of the fluid flows and/or inflows, a multivariate model can be developed to identify fluid flow and the composition of the flow based on building a predicted data set for the flow using the inflow data. In this multivariate model, the volume of a hydrocarbon gas phase, a hydrocarbon liquid phase, and an aqueous phase can be predicted using the inflow profiling analysis. In order to predict a volume of each phase, a magnitude of one or more frequency domain features associated with each phase can be used to determine a volume of fluid. The resulting volume data can then be aggregated across each inflow location to predict the total volume of each fluid phase flowing within the conduit at a given location. This type of multivariate model can be developed using regularized multivariate linear regression. Further, this type of data can be used to predict fluid phase and volume flows in a manner similar to that provided by a PLS disposed in a wellbore. The data can then be compared to further refine and/or develop the multivariate model based on a comparison with actual PLS data from the wellbore. Other multivariate models can also be developed using the processes described herein. In some embodiments, test data can be generated for an expected event within a wellbore using a flow loop or flow test apparatus as disclosed herein. The desired event or flow can be created, and the test data can be captured. The resulting labeled data sets can be used to train one or more multivariate models to determine the presence of the event using one or more frequency domain features. As an example of an additional multivariate model, sand inflow and/or flow in a fluid phase within a conduit can be modeled. The sand flow can be modeled in different fluid phases, at different sand amounts, in different orientations, and through different types of production assemblies, pipes, annuli, and the like. The resulting acoustic data can be used in the model development process as disclosed herein to determine one or more multivariate models indicative of the presence of sand in an inflowing fluid in one or more fluid phases and/or in a flowing fluid within the wellbore within one or more fluid phases. Such multivariate model may then be used with detected acoustic data to determine if sand is present in various fluids while allowing for discrimination between sand inflow and/or sand flow along the wellbore. In some embodiments, the model at600′ can be developed using machine learning. In order to develop and validate the model, data having known fluid flows and acoustic signals can be used as the basis for training and/or developing the model parameters. This data set can be referred to as a labeled data set (e.g., a data set for which the flow regime and/or inflow location is already known) that can be used for training the models (e.g., the multivariate model) in some instances. In some embodiments, the known data can be data from a wellbore having flow measured by various means. In some embodiments, the data can be obtained using a test setup where known quantities of various fluids (e.g., gas, hydrocarbon liquids, aqueous liquids, etc.) can be introduced at controlled point to generate controlled fluid flow and/or inflows. At least a portion of the data can be used to develop the model, and optionally, a portion of the data can be used to test the model once it is developed. FIG.7illustrates a flow diagram of a method II of developing a fluid identification or flow model according to some embodiments. The method can comprise, at900, obtaining acoustic data or signals from a plurality of flow and/or inflow tests in which one or more fluids of a plurality of fluids are introduced into a a conduit at predetermined locations spanning a length of the conduit, wherein the plurality of fluids comprise a hydrocarbon gas, a hydrocarbon liquid, an aqueous fluid, or a combination thereof, and wherein the acoustic signal comprises acoustic samples across a portion of the conduit. The one or more fluids of a plurality of fluids can be introduced into a flowing fluid to determine the inflow signatures for fluid(s) entering flow fluids. In some embodiments, the one or more fluids can be introduced in a relatively stagnant fluid. This may help to model the lower or lowest producing portion of the well where no bulk fluid flow may be passing through the wellbore at the point at which the fluid enters the well. This may be tested to obtain the signature of fluid inflow into a fluid within the wellbore that may not be flowing. The acoustic signal can be obtained by any means known to those of skill in the art. In some embodiments, the acoustic data can be from field data where the data is verified by other test instruments. In some embodiments, the acoustic signal is obtained from a sensor within or coupled to the conduit for each inflow test of the plurality of inflow tests. The sensor can be disposed along the length of the conduit, and the acoustic signal that is obtained can be indicative of an acoustic source along a length of the conduit. The sensor can comprise a fiber optic cable disposed within the conduit, or in some embodiments, coupled to the conduit (e.g., on an outside of the conduit). The conduit can be a continuous section of a tubular, and in some embodiments, the can be disposed in a loop. While described as being a loop in some circumstances, a single section of pipe or tubular can also be used with additional piping used to return a portion of the fluid to the entrance of the conduit. The configuration of the tubular test arrangement can be selected based on an expected operating configuration. A generic test arrangement may comprise a single tubular having one or more injection points. The acoustic sensor can be disposed within the tubular or coupled to an exterior of the tubular. In some embodiments, other arrangement such as pipe-in-pipe arrangements designed to mimic a production tubular in a casing string can be used for the flow tests. The sensor can be disposed within the inner pipe, in an annulus between the inner pipe and outer pipe, or coupled to an exterior of the outer pipe. The disposition of the sensor and the manner in which it is coupled within the test arrangement can be the same or similar to how it is expected to be disposed within a wellbore. Any number of testing arrangements and sensor placements can be used, thereby allowing for test data corresponding to an expected completion configuration. Over time, a library of configurations and resulting test data can be developed to allow for future models to be developed based on known, labeled data used to train multivariate models. In some embodiments, the conduit comprises a flow loop, and the flowing fluid comprises an aqueous fluid, a hydrocarbon fluid, a gas, or a combination thereof. The flowing fluid can comprise a liquid phase, a multi-phase mixed liquid, or a liquid-gas mixed phase. In some embodiments, the flowing fluid within the conduit can have a flow regime including, but not limited to, laminar flow, plugging flow, slugging flow, annular flow, turbulent flow, mist flow, bubble flow, or any combination thereof. Within these flow regimes, the flow and/or inflow can be time based. For example, a fluid inflow can be laminar over a first time interval followed by slugging flow over a second time period, followed by a return to laminar or turbulent flow over a third time period. Thus, the specific flow regimes can be interrelated and have periodic or non-periodic flow regime changes over time. An assembly1for performing inflow tests is provided inFIG.8A. Assembly1comprises a conduit5into or onto which a sensor2(e.g., a fiber optic cable) is disposed. In some embodiments, the fiber optic cable2can be disposed within conduit5. In some embodiments, the fiber optic cable2can be disposed along an outside of the conduit5, for example, coupled to an exterior of the conduit. The fiber optic cable can be disposed along a length L of conduit5. In some embodiments, other types of sensors can be used such as point source acoustic or vibration sensors. A line40may be configured for introducing background fluid into a first end6of conduit5. One or a plurality of injection points10can be disposed along length L of conduit5. An assembly for performing inflow tests can comprise any number of injection points. For example, an assembly for performing inflow tests according to this disclosure can comprise 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more injection points10. For example, in the embodiment ofFIG.8A, four injection points10A,10B,10C, and10D are disposed along length L of conduit5. By way of example, a length L of conduit5may be in a range of from about 10 to about 100 meters, from about 20 to about 80 meters, or from about 30 to about 70 meters, for example, 30, 40, 45, 50, 55, 60, 65, or 70 meters. The injection points may be positioned a spacing distance apart with regard to each other and/or first end6and second end7of conduit5. The spacing distance can be selected based on a spatial resolution of the sensor system such that the injection points can be distinguished from each other in the resulting testing data. When point source sensors are used, the type of sensors can be considered in selecting the spacing distance. The spacing distance may also be selected, at least in part, to be sufficient to allow for a desired flow regime to develop between injection points. In some embodiments, first injection point10A can be positioned a spacing distance S1from first end6of conduit5and a second spacing S2from second injection point10B. Second injection point10B can be positioned a spacing distance S3from third injection point10C. Third injection point10C can be positioned a spacing distance S4from a fourth injection point10D. Fourth injection point10D can be positioned a spacing distance S5from a transparent section20of conduit5. Transparent section20can be utilized to visually confirm the flow regime within conduit5. The visual appearance information can be recorded as part of the test data set. A production logging system (PLS) may be positioned within a spacing distance S6of second end7of conduit5and operable to compare data received via sensor or fiber optic cable2. In some embodiments, without limitation, the spacing distances between injection points (e.g., spacing distances S2, S3, and S4) are in a range of from about 2 to about 20 m, from about 2 to about 15 m, or from about 10 to about 15 m apart. In some embodiments, the first and last injection points are at least 5, 6, 7, 8, 9, or 10 m from a closest end (e.g., from first end6or second end7) of conduit5. For example, spacing distances S1and S5can be at least 5, 6, 7, 8, 9, or 10 meters, in embodiments. The conduit5can be disposed at any angle, including any angle between, and including, horizontal to vertical. The angle of the conduit, along with the fluid composition and flow rates can affect the flow regimes within the conduit. For example, a gas phase may collect along a top of a horizontally oriented conduit5as compared to a bubbling or slugging flow in a vertical conduit. Thus, the flow regime can change based on an orientation of the conduit even with the same fluid flow rates and compositions. The angle can be selected to represent those conditions that are being modeled to match those found in a wellbore, and the angle of the conduit can become part of the data obtained from the test set up. Background fluid can be injected into line40in any of the flow regimes noted herein, for example, laminar flow, plugging flow, slugging flow, annular flow, turbulent flow, mist flow, and/or bubble flow, which may be visually confirmed through transparent section20of assembly1. The background flowing fluid can comprise a liquid phase, a multi-phase mixed liquid, and/or a liquid-gas mixed phase. The inflow tests can include various combinations of injected fluid and background flowing fluid. For example, a single phase (e.g., water, gas, or hydrocarbon liquid) can be injected into a background fluid comprising one or multiple phases (e.g., water, gas, and/or hydrocarbon liquid) flowing in a particular flow regime. Inflow tests can also be performed for injection of multiphase fluids (e.g., hydrocarbon liquid and gas, hydrocarbon liquid and water, hydrocarbon liquid, water, and gas) into a background fluid comprising one or multiple phases (e.g., water, gas, and/or hydrocarbon liquid) flowing in a particular flow regime. In order to understand the variability in the measured signal for testing purposes, the flow for each type of flow can be incremented over time. For example, the flow and/or injection rate can be varied in steps over a time period. Each rate of flow or injection rate can be held constant over a time period sufficient to obtain a useable sample data set. The time period should be sufficient to identify variability in the signal at a fixed rate. For example, between about 1 minute and about 30 minutes of data can be obtained at each stepped flow rate before changing the flow rate to a different flow or injection rate. As depicted in the schematic ofFIG.8B, which is a schematic3showing wellbore depths corresponding to injection points ofFIG.8A, the inflow tests can be calibrated to a certain reservoir depth, for example, by adjusting the fiber optic signal for the test depth. For example, injection points10A,10B,10C, and10D can correspond to inflow depths D1, D2, D3, and D4, respectively. As an example, a length of fiber optic cable can be used that corresponds to typical wellbore depths (e.g., 3,000 m to 10,000 m, etc.). The resulting acoustic signals can then represent or be approximations of acoustic signals received under wellbore conditions. During the flow tests, acoustic data can be obtained under known flow conditions. The resulting acoustic data can then be used as training and/or test data for purposes of preparing the fluid flow model. For example, a first portion of the data can be used with machine learning techniques to train the fluid flow model, and a second portion of the data can be used to verify the results from the fluid flow model once it is developed. Using the test data obtained from the flow apparatus, the method of developing the fluid flow model can include determining one or more frequency domain features from the acoustic signal for at least a portion of the data from the plurality of fluid inflow tests. The one or more frequency domain features can be obtained across the portion of the conduit including the predetermined locations at910, and training the fluid flow model can use the one or more frequency domain features for a plurality of the tests and the predetermined locations at920. The training of the fluid flow model can use machine learning, including any supervised or unsupervised learning approach. For example, the fluid flow model can be a neural network, a Bayesian network, a decision tree, a logistical regression model, a normalized logistical regression model, k-means clustering or the like. In some embodiments, the fluid flow model can be developed and trained using a logistic regression model. As an example for training of a model used to determine the presence or absence of a hydrocarbon gas phase, the training of the fluid flow model at920can begin with providing the one or more frequency domain features to the logistic regression model corresponding to one or more inflow tests where the one or more fluids comprise a hydrocarbon gas. The one or more frequency domain features can be provided to the logistic regression model corresponding to one or more inflow tests where the one or more fluids do not comprise a hydrocarbon gas. A first multivariate model can be determined using the one or more frequency domain features as inputs. The first multivariate model can define a relationship between a presence and an absence of the hydrocarbon gas in the one or more fluids. Similarly, the fluid flow model can include a logistic regression model for an aqueous fluid, and the fluid flow model can be trained at920by providing the one or more frequency domain features to the logistic regression model corresponding to one or more inflow tests where the one or more fluids comprise an aqueous fluid. The one or more frequency domain features can also be provided to the logistic regression model corresponding to one or more inflow tests where the one or more fluids do not comprise a aqueous fluid. A second multivariate model can then be determined using the one or more frequency domain features as inputs where the second multivariate model defines a relationship between a presence and an absence of the aqueous fluid in the one or more fluids. The fluid flow model can also include a logistic regression model for hydrocarbon liquids. Training the fluid flow model at920can include providing the one or more frequency domain features to the logistic regression model corresponding to one or more inflow tests of the plurality of inflow tests where the one or more fluids comprise a hydrocarbon liquid. One or more frequency domain features can also be provided to the logistic regression model corresponding to one or more inflow tests where the one or more fluids do not comprise a hydrocarbon liquid. A third multivariate model can then be determined using the one or more frequency domain features as inputs, where the third multivariate model defines a relationship between a presence and an absence of the hydrocarbon liquid in the one or more fluids. The one or more frequency domain features can comprise any frequency domain features noted hereinabove as well as combinations and transformations thereof. For example, In some embodiments, the one or more frequency domain features comprise a spectral centroid, a spectral spread, a spectral roll-off, a spectral skewness, an RMS band energy, a total RMS energy, a spectral flatness, a spectral slope, a spectral kurtosis, a spectral flux, a spectral autocorrelation function, combinations and/or transformations thereof, or any normalized variant thereof. In some embodiments, the one or more frequency domain features comprise a normalized variant of the spectral spread (NVSS) and/or a normalized variant of the spectral centroid (NVSC). In the fluid flow model, the multivariate model equations can use the frequency domain features or combinations or transformations thereof to determine when a specific fluid or flow regime is present. The multivariate model can define a threshold, decision point, and/or decision boundary having any type of shapes such as a point, line, surface, or envelope between the presence and absence of the specific fluid or flow regime. In some embodiments, the multivariate model can be in the form of a polynomial, though other representations are also possible. When models such a neural networks are used, the thresholds can be based on node thresholds within the model. As noted herein, the multivariate model is not limited to two dimensions (e.g., two frequency domain features or two variables representing transformed values from two or more frequency domain features), and rather can have any number of variables or dimensions in defining the threshold between the presence or absence of the fluid or flow regime. When used, the detected values can be used in the multivariate model, and the calculated value can be compared to the model values. The presence of the fluid or flow regime can be indicated when the calculated value is on one side of the threshold and the absence of the fluid or flow regime can be indicated when the calculated value is on the other side of the threshold. Thus, each multivariate model can, in some embodiments, represent a specific determination between the presence of absence of a fluid or flow regime. Different multivariate models, and therefore thresholds, can be used for each fluid and/or flow regime, and each multivariate model can rely on different frequency domain features or combinations or transformations of frequency domain features. Since the multivariate models define thresholds for the determination and/or identification of specific fluids, the multivariate models and fluid flow model using such multivariate models can be considered to be event signatures for each type of fluid flow and/or inflow (including flow regimes, etc.). Once the model is trained or developed, the fluid flow model can be verified or validated. In some embodiments, the plurality of the tests used for training the fluid flow model can be a subset of the plurality of flow tests, and the tests used to validate the models can be another subset of the plurality of flow tests. A method of developing a fluid flow model according to this disclosure can further include the validation of the trained fluid flow model using the acoustic signals from one or more tests and the predetermined locations of the one or more tests at930. The validation process can include providing the acoustic signals from one or more of the plurality of inflow tests and the predetermined locations of the one or more of the plurality of inflow tests to each of the first multivariate model, the second multivariate model, and the third multivariate model. A presence or absence of at least one of the gas in the one or more fluids, the aqueous fluid in the one or more fluids, or the hydrocarbon liquid in the one or more fluids based on an output of each of the first multivariate model, the second multivariate model, and the third multivariate model can then be determined. The fluid flow model at930can be validated by comparing the predicted presence or absence of the gas in the one or more fluids, the aqueous fluid in the one or more fluids, or the hydrocarbon liquid in the one or more fluids to the actual presence as known from the test data. Should the accuracy of the fluid flow model be sufficient (e.g., meeting a confidence threshold), then the fluid flow model can be used to detect and/or identify fluids within a wellbore. If the accuracy is not sufficient, then additional data and training or development can be carried out to either find new frequency domain feature relationships to define the multivariate models or improve the derived multivariate models to more accurately predict the presence and identification of the fluids. In this process, the development, validation, and accuracy checking can be iteratively carried out until a suitable fluid flow model is determined. Using the validation process, a confidence level can be determined based on the validating at940; and a remediation procedure can be performed based on the confidence level at950. With reference toFIG.1, a method of identifying fluid inflow according to this disclosure can further comprise determining relative amounts of gas phase inflow, aqueous phase inflow, and hydrocarbon liquid phase inflow at700. Determining relative amounts of gas phase inflow, aqueous phase inflow, and hydrocarbon liquid phase inflow at700can comprise determining an amplitude of each of the determined at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow over a time period at the identified one or more fluid inflow locations; and determining a relative contribution of each of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow based on the amplitude of each of the identified at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow over the time period. In some embodiments, the amplitude and/or spectral power of each portion of the acoustic signal can be compared to produced volumes of each fluid. The relative power originated from various inflow locations can be compared and assigned a proportion of the overall produced fluid flow based on the frequency domain features such as the amplitude or spectral power. The volumes of each fluid flowing in the wellbore tubulars can be confirmed using the fluid flow model, and the relative amounts determined at the fluid inflow locations can be used to determine the amounts present in the fluid flow in the wellbore tubulars at points downstream of the inflow locations. This can allow for an estimate of the volume of each fluid present at various points in the wellbore to be determined. In an embodiment, a method of identifying fluid flow can comprise determining relative amounts of gas phase inflow, aqueous phase inflow, and hydrocarbon liquid phase inflow. Determining relative amounts of gas phase inflow, aqueous phase inflow, and hydrocarbon liquid phase inflow can comprise determining an amplitude of each of the determined at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow over a time period at the identified one or more fluid inflow locations; and determining a relative contribution of each of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow based on the amplitude of each of the identified at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow over the time period. The method can comprise aggregating the determined amounts of each of gas phase inflow, aqueous phase inflow, and hydrocarbon liquid phase inflow along the length of the conduit (e.g., the production tubing), and determining fluid flow volumes, flow rates, and/or flow regimes within the conduit based on the determined amounts of each of gas phase inflow, aqueous phase inflow, and hydrocarbon liquid phase inflow. A method of identifying fluid inflow according to this disclosure can further comprise determining and/or performing a remediation procedure at800. The remediation procedure determined and/or performed can be based on the relative amounts of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow at700, the confidence level determined at650, or a combination thereof. A combination of the steps discussed herein can be utilized in a method of identifying fluid inflow according to this disclosure. For example, a method of determining fluid inflow can comprise obtaining an acoustic signal at100, determining one or a plurality of frequency domain features from the acoustic signal at300and identifying one or more fluid inflow locations from the one or the plurality of frequency domain features at500. Alternatively, a method of determining fluid inflow can comprise obtaining an acoustic signal at100, determining a plurality of frequency domain features from the acoustic signal at300, identifying one or more fluid inflow locations from one or more of the plurality of frequency domain features at500, and identifying at least one of a gas phase inflow, an aqueous phase inflow, or a hydrocarbon liquid phase inflow at the identified one or more fluid inflow locations using at least two of the plurality of frequency domain features at600. The identification method can use any of the fluid flow models described herein. Alternatively, a method of determining fluid inflow can comprise obtaining an acoustic signal at100, determining a plurality of frequency domain features from the acoustic signal at300, identifying one or more fluid inflow locations at500(via one or more of the one or the plurality of frequency domain features or in an alternative manner), and identifying at least one of a gas phase inflow, an aqueous phase inflow, or a hydrocarbon liquid phase inflow at the identified one or more fluid inflow locations using at least two of the plurality of frequency domain features at600. This identification method can use any of the fluid flow models described herein. With reference back toFIG.6, when fluid inflow events have been identified as having occurred during the sample data measurement period, which can be in real time or near real time, various outputs can be generated to display or indicate the presence at406of the one or more fluid inflow events that are identified at500and/or600. In addition to detecting the presence of one or more events (e.g, fluid inflow, gas phase inflow, hydrocarbon liquid phase inflow, aqueous phase inflow) at a depth or location in the wellbore114, the analysis software executing on the processor168can be used to visualize the fluid inflow locations or relative amounts over a computer network for visualization on a remote location. For example, as depicted inFIG.9, an output can comprise one or more of a plot of the gas phase inflow as a function of depth in the well and time as depicted in panel A, a plot of the hydrocarbon liquid phase inflow as a function of depth in the well and time as depicted in panel B, a plot of the aqueous phase inflow as a function of depth in the well and time, as depicted in panel C. The plots can be overlaid to provide a single plot depicting the gas phase inflow, aqueous phase inflow, and hydrocarbon liquid phase inflow as a function of depth in the well and time, as depicted in panel D ofFIG.9. Alternatively or additionally, the data can be integrated to provide a cumulative display of the amounts of gas phase inflow, aqueous phase inflow, and hydrocarbon liquid phase inflow as a function of depth in the well and time, as depicted in panel E ofFIG.9. The computation of a fluid inflow event log may be done repeatedly, such as every second, and later integrated/averaged for discrete time periods—for instance, at times of higher well drawdowns, to display a time-lapsed event log at various stages of the production process (e.g., from baseline shut-in, from during well ramp-up, from steady production, from high drawdown/production rates etc.). The time intervals may be long enough to provide suitable data, though longer times may result in larger data sets. In an embodiment, the time integration may occur over a time period between about 0.1 seconds to about 10 seconds, or between about 0.5 seconds and about a few minutes or even hours. The resulting fluid inflow event log(s) computed every second can be stored in the memory170or transferred across a computer network, to populate a fluid inflow event database. The data can be used to generate an integrated fluid inflow event log at each fluid inflow event depth sample point along the length of the optical fiber162along with a synchronized timestamp that indicates the times of measurement. In producing a visualization fluid inflow event log, the values for depth sections that do not exhibit fluid inflow can be set to zero. This allows those depth points or zones exhibiting fluid inflow to be easily identified. As an example, the analysis software executing on the processor168can be used to visualize fluid inflow locations or relative fluid inflow amounts over a computer network for visualization on a remote location. The computation of a ‘fluid inflow log’ may be done repeatedly, such as every second, and later integrated/averaged for discrete time periods—for instance, at times of higher well drawdowns, to display a time-lapsed fluid inflow log at various stages of the production process (e.g., from baseline shut-in, from during well ramp-up, from steady production, from high drawdown/production rates etc.). The time intervals may be long enough to provide suitable data, though longer times may result in larger data sets. In an embodiment, the time integration may occur over a time period between about 0.1 seconds to about 10 seconds, or between about 0.5 seconds and about a few minutes or even hours. Fluid inflow logs computed every second can be stored in the memory170or transferred across a computer network, to populate an event database. The data stored/transferred in the memory170for one or more of the data set depths may be stored every second. This data can be used to generate an integrated fluid inflow log at each event depth sample point along the length of the optical fiber162along with a synchronized timestamp that indicates the times of measurement. The data output by the system may generally indicate one or more fluid inflow locations or depths, a composition (e.g., oil, gas, water) of the inflowing fluid at the indicated fluid inflow locations, and optionally, a relative amount of fluid inflow component(s) among the identified locations or depths and/or a qualitative indicator of fluid inflow component(s) entering the wellbore at a location. The data output can also indicate fluid flow locations within the wellbore tubulars and fluid compositions at those locations. If water or gas inflow is observed in the produced fluid (as determined by methods such as surface detectors, visual observation, etc.), but the location and/or amount of the water or gas inflow cannot be identified with sufficient clarity using the methods described herein, various actions can be taken in order to obtain a better visualization of the acoustic data. In an embodiment, the production rate can be temporarily increased. The resulting data analysis can be performed on the data during the increased production period. In general, an increased fluid flow rate into the wellbore may be expected to increase the acoustic signal intensity at the fluid inflow locations. This may allow a signal to noise ratio to be improved in order to more clearly identify fluid flow and/or inflow at one or more locations by, for example, providing for an increased signal strength. The water, gas, and/or hydrocarbon liquid flow and/or inflow energies can also be more clearly calculated based on the increased signal outputs. Once the zones of interest are identified, the production levels can be adjusted based on the water or gas inflow locations and amounts. Any changes in water and/or gas production amounts over time can be monitored using the techniques described herein and the operating conditions can be adjusted accordingly (e.g., dynamically adjusted, automatically adjusted, manually adjusted, etc.). In some embodiments, the change in the production rate can be used to determine a production rate correlation with the fluid inflow locations and flow rates at one or more points along the wellbore. In general, decreasing the production rate may be expected to reduce the fluid inflow rates and fluid flow rates. By determining production rate correlations with the fluid inflow rates, the production rate from the well and/or one or more zones can be adjusted to reduce the fluid inflow rate at the identified locations. For example, an adjustable production sleeve or choke can be altered to adjust specific fluid inflow rates in one or more production zones. If none of the production zones are adjustable, various workover procedures can be used to alter the production from specific zones. For example, various intake sleeves can be blocked off, zonal isolation devices can be used to block off production from certain zones, and/or some other operations can be carried out to reduce the amount of undesired fluid inflow (e.g., consolidation procedures, etc.). The same analysis procedure can be used with any of the fluid flow and/or inflow event signatures described herein. For example, the presence of one or more fluid inflow events (e.g., fluid inflow, gas inflow, water inflow, hydrocarbon liquid inflow) can be determined. In some embodiments, the location and or discrimination between events may not be clear. One or more characteristics of the wellbore can then be changed to allow a second measurement of the acoustic signal to occur. For example, the production rate can be changed, the pressures can be changed, one or more zones can be shut-in, or any other suitable production change. For example, the production rate can be temporarily increased. The resulting data analysis can be performed on the data during the increased production period. In general, an increased fluid flow rate into the wellbore may be expected to increase the acoustic signal intensity at certain event locations such as a gas inflow location, a water inflow location, a hydrocarbon liquid inflow location, or the like. This may allow a signal to noise ratio to be improved in order to more clearly identify one event relative to another at one or more locations by, for example, providing for an increased signal strength to allow the event signatures to be compared to the resulting acoustic signal. The event energies can also be more clearly calculated based on the increased signal outputs. Once the zones of interest are identified, the production levels can be adjusted based on the event locations and amounts. Any changes in the presence of the fluid inflow events over time can be monitored using the techniques described herein and the operating conditions can be adjusted accordingly (e.g., dynamically adjusted, automatically adjusted, manually adjusted, etc.). While the data analysis has been described above with respect to the system101, methods of identifying events within the wellbore (e.g., fluid inflow locations along the length of a wellbore, phase discrimination (e.g., gas, water, hydrocarbon liquid) of inflowing fluid, relative amounts of inflowing fluid components, etc.) can also be carried out using any suitable system. For example, the system ofFIG.2can be used to carry out the acoustic data acquisition, a separate system at a different time and/or location can be used with acoustic data to perform the fluid inflow event identification method, and/or the method can be performed using acoustic data obtained from a different type of acoustic sensor where the data is obtained in an electronic form useable with a device capable of performing the method. The acoustic signal can include data for all of the wellbore or only a portion of the wellbore. An acoustic sample data set can be obtained from the acoustic signal. In an embodiment, the sample data set may represent a portion of the acoustic signal for a defined depth range or point. In some embodiments, the acoustic signal can be obtained in the time domain. For example, the acoustic signal may be in the form of an acoustic amplitude relative to a collection time. The sample data set may also be in the time domain and be converted into the frequency domain using a suitable transform such as a Fourier transform. In some embodiments, the sample data set can be obtained in the frequency domain such that the acoustic signal can be converted prior to obtaining the sample data set. While the sample data set can be obtained using any of the methods described herein, the sample data set can also be obtained by receiving it from another device. For example, a separate extraction or processing step can be used to prepare one or more sample data sets and transmit them for separate processing using any of the processing methods or systems disclosed herein. Any of the systems and methods disclosed herein can be carried out on a computer or other device comprising a processor, such as the acquisition device160ofFIG.2.FIG.10illustrates a computer system780suitable for implementing one or more embodiments disclosed herein such as the acquisition device or any portion thereof. The computer system780includes a processor782(which may be referred to as a central processor unit or CPU) that is in communication with memory devices including secondary storage784, read only memory (ROM)786, random access memory (RAM)788, input/output (I/O) devices790, and network connectivity devices792. The processor782may be implemented as one or more CPU chips. It is understood that by programming and/or loading executable instructions onto the computer system780, at least one of the CPU782, the RAM788, and the ROM786are changed, transforming the computer system780in part into a particular machine or apparatus having the novel functionality taught by the present disclosure. It is fundamental to the electrical engineering and software engineering arts that functionality that can be implemented by loading executable software into a computer can be converted to a hardware implementation by well-known design rules. Decisions between implementing a concept in software versus hardware typically hinge on considerations of stability of the design and numbers of units to be produced rather than any issues involved in translating from the software domain to the hardware domain. Generally, a design that is still subject to frequent change may be preferred to be implemented in software, because re-spinning a hardware implementation is more expensive than re-spinning a software design. Generally, a design that is stable that will be produced in large volume may be preferred to be implemented in hardware, for example in an application specific integrated circuit (ASIC), because for large production runs the hardware implementation may be less expensive than the software implementation. Often a design may be developed and tested in a software form and later transformed, by well-known design rules, to an equivalent hardware implementation in an application specific integrated circuit that hardwires the instructions of the software. In the same manner as a machine controlled by a new ASIC is a particular machine or apparatus, likewise a computer that has been programmed and/or loaded with executable instructions may be viewed as a particular machine or apparatus. Additionally, after the system780is turned on or booted, the CPU782may execute a computer program or application. For example, the CPU782may execute software or firmware stored in the ROM786or stored in the RAM788. In some cases, on boot and/or when the application is initiated, the CPU782may copy the application or portions of the application from the secondary storage784to the RAM788or to memory space within the CPU782itself, and the CPU782may then execute instructions of which the application is comprised. In some cases, the CPU782may copy the application or portions of the application from memory accessed via the network connectivity devices792or via the I/O devices790to the RAM788or to memory space within the CPU782, and the CPU782may then execute instructions of which the application is comprised. During execution, an application may load instructions into the CPU782, for example load some of the instructions of the application into a cache of the CPU782. In some contexts, an application that is executed may be said to configure the CPU782to do something, e.g., to configure the CPU782to perform the function or functions promoted by the subject application. When the CPU782is configured in this way by the application, the CPU782becomes a specific purpose computer or a specific purpose machine. The secondary storage784is typically comprised of one or more disk drives or tape drives and is used for non-volatile storage of data and as an over-flow data storage device if RAM788is not large enough to hold all working data. Secondary storage784may be used to store programs which are loaded into RAM788when such programs are selected for execution. The ROM786is used to store instructions and perhaps data which are read during program execution. ROM786is a non-volatile memory device which typically has a small memory capacity relative to the larger memory capacity of secondary storage784. The RAM788is used to store volatile data and perhaps to store instructions. Access to both ROM786and RAM788is typically faster than to secondary storage784. The secondary storage784, the RAM788, and/or the ROM786may be referred to in some contexts as computer readable storage media and/or non-transitory computer readable media. I/O devices790may include printers, video monitors, liquid crystal displays (LCDs), touch screen displays, keyboards, keypads, switches, dials, mice, track balls, voice recognizers, card readers, paper tape readers, or other well-known input devices. The network connectivity devices792may take the form of modems, modem banks, Ethernet cards, universal serial bus (USB) interface cards, serial interfaces, token ring cards, fiber distributed data interface (FDDI) cards, wireless local area network (WLAN) cards, radio transceiver cards that promote radio communications using protocols such as code division multiple access (CDMA), global system for mobile communications (GSM), long-term evolution (LTE), worldwide interoperability for microwave access (WiMAX), near field communications (NFC), radio frequency identity (RFID), and/or other air interface protocol radio transceiver cards, and other well-known network devices. These network connectivity devices792may enable the processor782to communicate with the Internet or one or more intranets. With such a network connection, it is contemplated that the processor782might receive information from the network, or might output information to the network (e.g., to an event database) in the course of performing the above-described method steps. Such information, which is often represented as a sequence of instructions to be executed using processor782, may be received from and outputted to the network, for example, in the form of a computer data signal embodied in a carrier wave. Such information, which may include data or instructions to be executed using processor782for example, may be received from and outputted to the network, for example, in the form of a computer data baseband signal or signal embodied in a carrier wave. The baseband signal or signal embedded in the carrier wave, or other types of signals currently used or hereafter developed, may be generated according to several methods well-known to one skilled in the art. The baseband signal and/or signal embedded in the carrier wave may be referred to in some contexts as a transitory signal. The processor782executes instructions, codes, computer programs, scripts which it accesses from hard disk, floppy disk, optical disk (these various disk based systems may all be considered secondary storage784), flash drive, ROM786, RAM788, or the network connectivity devices792. While only one processor782is shown, multiple processors may be present. Thus, while instructions may be discussed as executed by a processor, the instructions may be executed simultaneously, serially, or otherwise executed by one or multiple processors. Instructions, codes, computer programs, scripts, and/or data that may be accessed from the secondary storage784, for example, hard drives, floppy disks, optical disks, and/or other device, the ROM786, and/or the RAM788may be referred to in some contexts as non-transitory instructions and/or non-transitory information. In an embodiment, the computer system780may comprise two or more computers in communication with each other that collaborate to perform a task. For example, but not by way of limitation, an application may be partitioned in such a way as to permit concurrent and/or parallel processing of the instructions of the application. Alternatively, the data processed by the application may be partitioned in such a way as to permit concurrent and/or parallel processing of different portions of a data set by the two or more computers. In an embodiment, virtualization software may be employed by the computer system780to provide the functionality of a number of servers that is not directly bound to the number of computers in the computer system780. For example, virtualization software may provide twenty virtual servers on four physical computers. In an embodiment, the functionality disclosed above may be provided by executing the application and/or applications in a cloud computing environment. Cloud computing may comprise providing computing services via a network connection using dynamically scalable computing resources. Cloud computing may be supported, at least in part, by virtualization software. A cloud computing environment may be established by an enterprise and/or may be hired on an as-needed basis from a third party provider. Some cloud computing environments may comprise cloud computing resources owned and operated by the enterprise as well as cloud computing resources hired and/or leased from a third party provider. In an embodiment, some or all of the functionality disclosed above may be provided as a computer program product. The computer program product may comprise one or more computer readable storage medium having computer usable program code embodied therein to implement the functionality disclosed above. The computer program product may comprise data structures, executable instructions, and other computer usable program code. The computer program product may be embodied in removable computer storage media and/or non-removable computer storage media. The removable computer readable storage medium may comprise, without limitation, a paper tape, a magnetic tape, magnetic disk, an optical disk, a solid state memory chip, for example analog magnetic tape, compact disk read only memory (CD-ROM) disks, floppy disks, jump drives, digital cards, multimedia cards, and others. The computer program product may be suitable for loading, by the computer system780, at least portions of the contents of the computer program product to the secondary storage784, to the ROM786, to the RAM788, and/or to other non-volatile memory and volatile memory of the computer system780. The processor782may process the executable instructions and/or data structures in part by directly accessing the computer program product, for example by reading from a CD-ROM disk inserted into a disk drive peripheral of the computer system780. Alternatively, the processor782may process the executable instructions and/or data structures by remotely accessing the computer program product, for example by downloading the executable instructions and/or data structures from a remote server through the network connectivity devices792. The computer program product may comprise instructions that promote the loading and/or copying of data, data structures, files, and/or executable instructions to the secondary storage784, to the ROM786, to the RAM788, and/or to other non-volatile memory and volatile memory of the computer system780. In some contexts, the secondary storage784, the ROM786, and the RAM788may be referred to as a non-transitory computer readable medium or a computer readable storage media. A dynamic RAM embodiment of the RAM788, likewise, may be referred to as a non-transitory computer readable medium in that while the dynamic RAM receives electrical power and is operated in accordance with its design, for example during a period of time during which the computer system780is turned on and operational, the dynamic RAM stores information that is written to it. Similarly, the processor782may comprise an internal RAM, an internal ROM, a cache memory, and/or other internal non-transitory storage blocks, sections, or components that may be referred to in some contexts as non-transitory computer readable media or computer readable storage media. Having described various systems and methods herein, specific embodiments can include, but are not limited to: In a first embodiment, a method of identifying inflow locations along a wellbore comprises: obtaining an acoustic signal from a sensor within the wellbore, wherein the acoustic signal comprises acoustic samples across a portion of a depth of the wellbore; determining a plurality of frequency domain features from the acoustic signal, wherein the plurality of frequency domain features are obtained across a plurality of depth intervals within the portion of the depth of the wellbore, and wherein the plurality of frequency domain features comprise at least two different frequency domain features; and identifying at least one of a gas phase inflow, an aqueous phase inflow, or a hydrocarbon liquid phase inflow using the plurality of the frequency domain features at one or more fluid inflow locations. A second embodiment can include the method of the first embodiment, further comprising: identifying the one or more fluid inflow locations within the plurality of depth intervals using one or more frequency domain features of the plurality of frequency domain features. A third embodiment can include the method of any one of the first or the second embodiment, wherein the one or more frequency domain features comprise a spectral flatness. A fourth embodiment can include the method of any one of the first through the third embodiments, wherein the sensor comprises a fiber optic cable disposed within the wellbore. A fifth embodiment can include the method of any one of the first through the fourth embodiments, wherein the plurality of frequency domain features comprises at least two of: a spectral centroid, a spectral spread, a spectral roll-off, a spectral skewness, an RMS band energy, a total RMS energy, a spectral flatness, a spectral slope, a spectral kurtosis, a spectral flux, a spectral autocorrelation function, or a normalized variant thereof. A sixth embodiment can include the method of any one of the first through the fifth embodiments, further comprising: denoising the acoustic signal prior to determining the plurality of frequency domain features. A seventh embodiment can include the method of the sixth embodiment, wherein denoising the acoustic signal comprises median filtering the acoustic data. An eighth embodiment can include the method of any of the first through the seventh embodiments, further comprising: calibrating the acoustic signal. A ninth embodiment can include the method of any one of the first through the eighth embodiments, further comprising: normalizing the one or more frequency domain features prior to identifying the one or more inflow locations using the one or more frequency domain features. A tenth embodiment can include the method of any one of the first through the ninth embodiments, wherein identifying the one or more fluid inflow locations comprises: identifying a background fluid flow signature using the acoustic signal; and removing the background fluid flow signature from the acoustic signal prior to identifying the one or more fluid inflow locations. An eleventh embodiment can include the method of any one of the first through the ninth embodiments, wherein identifying the one or more fluid inflow locations comprises: identifying one or more anomalies in the acoustic signal using the one or more frequency domain features of the plurality of frequency domain features; and selecting the depth intervals of the one or more anomalies as the one or more inflow locations. A twelfth embodiment can include any one of the first through the eleventh embodiments, wherein identifying at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow comprises: providing the plurality of frequency domain features to a logistic regression model for each of the gas phase inflow, the aqueous phase inflow, and the hydrocarbon liquid phase inflow; and determining that at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow is present based on the logistic regression model. A thirteenth embodiment can include the method of the twelfth embodiment, wherein the logistic regression model uses a first multivariate model having the plurality of frequency domain features as inputs to determine when the gas phase inflow is present, wherein the logistic regression model uses a second multivariate model having the plurality of frequency domain features as inputs to determine when the aqueous phase inflow is present, and wherein the logistic regression model uses a third multivariate model having the plurality of frequency domain features as inputs to determine when the hydrocarbon liquid phase inflow is present. A fourteenth embodiment can include the method of any one of the first through the thirteenth embodiments, further comprising: determining an amplitude of each of the identified at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow over a time period; and determining a relative contribution of each of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow based on the amplitude of each of the identified at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow over the time period. A fifteenth embodiment can include the method of the fourteenth embodiment, further comprising: determining a remediation procedure based on the relative contribution of each of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow; and performing the remediation procedure. A sixteenth embodiment can include the method of any one of the twelfth through the fifteenth embodiments, wherein the plurality of frequency domain features comprise a normalized variant of the spectral spread and a normalized variant of the spectral centroid, and wherein the logistic regression model defines a relationship between a presence or absence of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow. A seventeenth embodiment can include the method of any one of the first through the sixteenth embodiments, further comprising: determining a confidence level for the identification of the at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow; and performing a remediation procedure based on the confidence level. An eighteenth embodiment can include the method of any one of the first through the seventeenth embodiments, wherein obtaining the acoustic signal from the sensor within the wellbore occurs from between 30 minutes and 4 hours. A nineteenth embodiment can include the method of any one of the first through the eighteenth embodiments, wherein the sensor comprises a fiber optic cable disposed within a production tubing within the wellbore. A twentieth embodiment can include the method of any one of the first through the nineteenth embodiments, wherein identifying the at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow using the plurality of the frequency domain features comprises: identifying the at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow using a derivative of at least one of the plurality of the frequency domain features. A twenty-first embodiment can include the method of any one of the first through the twentieth embodiments, wherein identifying the at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow using the plurality of the frequency domain features comprises: identifying the at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow using a ratio between at least two of the plurality of the frequency domain features. In a twenty-second embodiment, a method of developing an inflow location model for a wellbore can comprise: performing a plurality of inflow tests, wherein each inflow test comprises introducing one or more fluids of a plurality of fluids into a flowing fluid within a conduit at predetermined locations, and wherein the plurality of fluids comprise a hydrocarbon gas, a hydrocarbon liquid, an aqueous fluid, or a combination thereof; obtaining an acoustic signal from a sensor within the conduit for each inflow test of the plurality of inflow tests, wherein the acoustic signal comprises acoustic samples across a portion of the conduit including the predetermined locations; determining one or more frequency domain features from the acoustic signal for each of the plurality of inflow tests, wherein the one or more frequency domain features are obtained across the portion of the conduit including the predetermined locations; and training a fluid flow model using the one or more frequency domain features for a plurality of the tests and the predetermined locations. A twenty-third embodiment can include the method of the twenty-second embodiment, further comprising: validating the fluid flow model using the acoustic signals from one or more of the tests and the predetermined locations of the plurality of tests. A twenty-fourth embodiment can include the method of the twenty-second or the twenty-third embodiment, wherein the conduit comprises a flow loop, and wherein the flowing fluid comprises an aqueous fluid, a hydrocarbon fluid, a gas, or a combination thereof. A twenty-fifth embodiment can include the method of any one of the twenty-second through the twenty-fourth embodiments, wherein the flowing fluid comprises a liquid phase, a multi-phase mixed liquid, or a liquid-gas mixed phase. A twenty-sixth embodiment can include the method of any one of the twenty-second through the twenty-fifth embodiments, wherein the plurality of the tests used for training the fluid flow model is a subset of the plurality of inflow tests. A twenty-seventh embodiment can include the method of any one of the twenty-second through the twenty-sixth embodiments, wherein the fluid flow model comprises a logistic regression model, and wherein training the fluid flow model comprises: providing the one or more frequency domain features to the logistic regression model corresponding to one or more inflow tests of the plurality of inflow tests where the one or more fluids comprise a hydrocarbon gas; providing the one or more frequency domain features to the logistic regression model corresponding to one or more inflow tests of the plurality of inflow tests where the one or more fluids do not comprise a hydrocarbon gas; and determining a first multivariate model using the one or more frequency domain features as inputs, wherein the first multivariate model defines a relationship between a presence and an absence of the hydrocarbon gas in the one or more fluids. A twenty-eighth embodiment ca include the method of any one of the twenty-second through the twenty-seventh embodiments, wherein the fluid flow model comprises a logistic regression model, and wherein training the fluid flow model comprises: providing the one or more frequency domain features to the logistic regression model corresponding to one or more inflow tests of the plurality of inflow tests where the one or more fluids comprise an aqueous fluid; providing the one or more frequency domain features to the logistic regression model corresponding to one or more inflow tests of the plurality of inflow tests where the one or more fluids do not comprise a aqueous fluid; and determining a second multivariate model using the one or more frequency domain features as inputs, wherein the second multivariate model defines a relationship between a presence and an absence of the aqueous fluid in the one or more fluids. A twenty-ninth embodiment can include the method of any one of the twenty-second through the twenty-eighth embodiments, wherein the fluid flow model comprises a logistic regression model, and wherein training the fluid flow model comprises: providing the one or more frequency domain features to the logistic regression model corresponding to one or more inflow tests of the plurality of inflow tests where the one or more fluids comprise a hydrocarbon liquid; providing the one or more frequency domain features to the logistic regression model corresponding to one or more inflow tests of the plurality of inflow tests where the one or more fluids do not comprise a hydrocarbon liquid; and determining a third multivariate model using the one or more frequency domain features as inputs, wherein the third multivariate model defines a relationship between a presence and an absence of the hydrocarbon liquid in the one or more fluids. A thirtieth embodiment can include the method of any one of the twenty-second through the twenty-ninth embodiments, wherein the one or more frequency domain features comprise a normalized variant of the spectral spread (NVSS) and a normalized variant of the spectral centroid (NVSC). A thirty-first embodiment can include the method of any one of the twenty-ninth or the thirtieth embodiments, further comprising: providing the acoustic signals from one or more of the plurality of inflow tests and the predetermined locations of the plurality of tests to each of the first multivariate model, the second multivariate model, and the third multivariate model; determining a presence of at least one of the gas in the one or more fluids, the aqueous fluid in the one or more fluids, or the hydrocarbon liquid in the one or more fluids based on an output of each of the first multivariate model, the second multivariate model, and the third multivariate model; and validating the fluid flow model using at least a portion of the plurality of inflow tests, the predetermined locations of the plurality of tests, and the presence of at least one of the gas in the one or more fluids, an aqueous fluid in the one or more fluids, or the hydrocarbon liquid in the one or more fluids as determined from the first multivariate model, the second multivariate model, and the third multivariate model. A thirty-second embodiment can include the method of the thirty-first embodiment, further comprising: determining a confidence level based on the validating; and performing a remediation procedure based on the confidence level. A thirty-third embodiment can include the method of any one of the twenty-second through the twenty-sixth embodiments, wherein the fluid flow model is a neural network, a Bayesian network, a decision tree, a supervised learning algorithm, a logistical regression model, or a normalized logistical regression model. A thirty-fourth embodiment can include the method of any one of the twenty-second through the thirty-third embodiments, wherein the conduit is disposed in a loop. A thirty-fifth embodiment can include the method of any one of the twenty-second through the thirty-fourth embodiments, wherein the sensor comprises a fiber optic cable disposed within the conduit. A thirty-sixth embodiment can include the method of any one of the twenty-second through the thirty-fifth embodiments, wherein the flowing fluid within the conduit has a flow regime selected from the group consisting of: laminar flow, plugging flow, slugging flow, annular flow, turbulent flow, mist flow, and bubble flow. A thirty-seventh embodiment can include the method of any one of the twenty-second through the thirty-sixth embodiments, wherein the sensor is disposed along the length of the conduit, and wherein the acoustic signal is indicative of an acoustic source along a length of the conduit. In a thirty-eighth embodiment, a method a method of characterizing fluid inflow into a wellbore comprises: obtaining an acoustic signal from a sensor within the wellbore, wherein the acoustic signal comprises acoustic samples across a portion of a depth of the wellbore; determining a plurality of frequency domain features from the acoustic signal, wherein the plurality of frequency domain features are obtained across a plurality of depth intervals within the portion of the depth of the wellbore, and wherein the plurality of frequency domain features comprise at least two different frequency domain features; identifying one or more fluid inflow locations within the plurality of depth intervals using one or more frequency domain features of the plurality of frequency domain features; providing the plurality of frequency domain features at the identified one or more fluid inflow locations to a fluid flow model; and determining at least one of a gas phase inflow, an aqueous phase inflow, or a hydrocarbon liquid phase inflow at the identified one or more fluid inflow locations using the fluid flow model. A thirty-ninth embodiment can include the method of the thirty-eighth embodiment, further comprising: determining an amplitude of each of the determined at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow over a time period at the identified one or more fluid inflow locations; and determining a relative contribution of each of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow based on the amplitude of each of the identified at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow over the time period. A fortieth embodiment can include the method of the thirty-eighth or the thirty-ninth embodiments, wherein the fluid flow model comprises a logistic regression model, and wherein determining at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase using the fluid flow model comprises: providing the plurality of frequency domain features to the logistic regression model for each of the gas phase inflow, the aqueous phase inflow, and the hydrocarbon liquid phase inflow; and determining that at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow is present based on the logistic regression model. A forty-first embodiment can include the method of the fortieth embodiment, wherein the logistic regression model uses a first multivariate model having the plurality of frequency domain features as inputs to determine when the gas phase inflow is present, wherein the logistic regression model uses a second multivariate model having the plurality of frequency domain features as inputs to determine when the aqueous phase inflow is present, and wherein the logistic regression model uses a third multivariate model having the plurality of frequency domain features as inputs to determine when the hydrocarbon liquid phase inflow is present. A forty-second embodiment can include the method of the forty-first embodiment, wherein determining at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase using the fluid flow model comprises: using the plurality of frequency domain features at the identified one or more fluid inflow locations in the first multivariate model; using the plurality of frequency domain features at the identified one or more fluid inflow locations in the second multivariate model; using the plurality of frequency domain features at the identified one or more fluid inflow locations in the third multivariate model; comparing the plurality of frequency domain features to an output of the first multivariate model, an output of the second multivariate model, and an output of the third multivariate model; and identifying at least one of the gas phase inflow, the aqueous phase inflow, or the hydrocarbon liquid phase inflow based on the comparison of the plurality of frequency domain features to the output of the first multivariate model, the output of the second multivariate model, and the output of the third multivariate model. A forty-third embodiment can include the method of any one of the thirty-eighth through the forty-second embodiments, wherein the one or more frequency domain features comprise a normalized frequency domain feature. A forty-fourth embodiment can include the method of any one of the thirty-eighth through the forty-third embodiments, wherein identifying the one or more fluid inflow locations within the plurality of depth intervals using the one or more frequency domain features comprises: identifying the one or more fluid inflow locations within the plurality of depth intervals using a ratio of two or more frequency domain features. A forty-fifth embodiment can include the method of any one of the thirty-eighth through the forty-fourth embodiments, further comprising: calibrating the acoustic signal from the sensor prior to determining the plurality of frequency domain features. A forty-sixth embodiment can include the method of the forty-fifth embodiment, wherein calibrating the acoustic signal comprises: removing a background signal from the acoustic signal. A forty-seventh embodiment can include the method of the forty-fifth embodiment, wherein calibrating the acoustic signal comprises: identifying one or more anomalies within the acoustic signal; and removing one or more portions of the acoustic signal outside of the one or more anomalies. A forty-eighth embodiment can include a method of identifying inflow locations along a wellbore, the method comprising: obtaining an acoustic signal from a sensor within the wellbore, wherein the acoustic signal comprises acoustic samples across a portion of a depth of the wellbore; determining one or more frequency domain features from the acoustic signal, wherein the one or more frequency domain features are obtained across a plurality of depth intervals within the portion of the depth of the wellbore; and identifying one or more fluid inflow locations within the plurality of depth intervals using the one or more frequency domain features. A forty-ninth embodiment can include the method of the forty-eighth embodiment, further comprising identifying at least one of a gas phase inflow, an aqueous phase inflow, or a hydrocarbon liquid phase inflow at least two of the one or more frequency domain features at one or more of the one or more identified fluid inflow locations. A fiftieth embodiment can include the method of the forty-ninth embodiment, wherein the at least two frequency domain features are selected from a spectral centroid, a spectral spread, a spectral roll-off, a spectral skewness, an RMS band energy, a total RMS energy, a spectral flatness, a spectral slope, a spectral kurtosis, a spectral flux, a spectral autocorrelation function, or a normalized variant thereof. A fifty-first embodiment can include the method of any of the forty-eighth through the fiftieth embodiments, wherein identifying the one or more fluid inflow locations within the plurality of depth intervals using a single one of the one or more frequency domain features. A fifty-second embodiment can include the method of the fifty-first embodiment, wherein the single one of the one or more frequency domain features comprises the RMS band energy or a spectral flatness. While various embodiments in accordance with the principles disclosed herein have been shown and described above, modifications thereof may be made by one skilled in the art without departing from the spirit and the teachings of the disclosure. The embodiments described herein are representative only and are not intended to be limiting. Many variations, combinations, and modifications are possible and are within the scope of the disclosure. Alternative embodiments that result from combining, integrating, and/or omitting features of the embodiment(s) are also within the scope of the disclosure. Accordingly, the scope of protection is not limited by the description set out above, but is defined by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated as further disclosure into the specification and the claims are embodiment(s) of the present invention(s). Furthermore, any advantages and features described above may relate to specific embodiments, but shall not limit the application of such issued claims to processes and structures accomplishing any or all of the above advantages or having any or all of the above features. Additionally, the section headings used herein are provided for consistency with the suggestions under 37 C.F.R. 1.77 or to otherwise provide organizational cues. These headings shall not limit or characterize the invention(s) set out in any claims that may issue from this disclosure. Specifically and by way of example, although the headings might refer to a “Field,” the claims should not be limited by the language chosen under this heading to describe the so-called field. Further, a description of a technology in the “Background” is not to be construed as an admission that certain technology is prior art to any invention(s) in this disclosure. Neither is the “Summary” to be considered as a limiting characterization of the invention(s) set forth in issued claims. Furthermore, any reference in this disclosure to “invention” in the singular should not be used to argue that there is only a single point of novelty in this disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims issuing from this disclosure, and such claims accordingly define the invention(s), and their equivalents, that are protected thereby. In all instances, the scope of the claims shall be considered on their own merits in light of this disclosure, but should not be constrained by the headings set forth herein. Use of broader terms such as comprises, includes, and having should be understood to provide support for narrower terms such as consisting of, consisting essentially of, and comprised substantially of. Use of the term “optionally,” “may,” “might,” “possibly,” and the like with respect to any element of an embodiment means that the element is not required, or alternatively, the element is required, both alternatives being within the scope of the embodiment(s). Also, references to examples are merely provided for illustrative purposes, and are not intended to be exclusive. While preferred embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the scope or teachings herein. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the systems, apparatus, and processes described herein are possible and are within the scope of the disclosure. For example, the relative dimensions of various parts, the materials from which the various parts are made, and other parameters can be varied. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. Unless expressly stated otherwise, the steps in a method claim may be performed in any order. The recitation of identifiers such as (a), (b), (c) or (1), (2), (3) before steps in a method claim are not intended to and do not specify a particular order to the steps, but rather are used to simplify subsequent reference to such steps. Also, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component, whether electrically, mechanically, or otherwise. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein. | 153,256 |
11859489 | DETAILED DESCRIPTION OF NON-LIMITING EMBODIMENTS The present invention relates to an imaging agent for microseismic monitoring of subterranean formations such as those generated during hydraulic fracturing. The invention also pertains to an imaging agent, a method of producing the imaging agent, and the use of the imaging agent in a well or formation. The invention as described herein is particularly applicable to the use of an imaging agent for subterranean formation monitoring of energy production wells such as oil, gas, and geothermal; however, it will be appreciated that the invention is also intended for use in other seismic monitoring applications in which is it desirable to know flow passage in a well or other type of subterranean formation. The present invention utilizes the implosion energy of a base particle in a protected particle as the base particle fractures or collapses under hydrostatic pressure for microseismic monitoring of subterranean formations. The fracturing or collapsing of the base particle generates an acoustic sound or emission that can be sensed by one or more sensors (e.g., subterranean sensors, etc.) such as hydrophones, geophones, and fiber optic sensors. The protected particle is configured to be a pumpable microseismic emitting agent that can be pumped and placed with hydraulic fracture proppant in a well or formation, and which protected particle can be used to provide accurate microseismic mapping of the well or formation during and/or after the fracturing and/or propping of the well or formation. Two non-limiting examples of protected particles in accordance with the present invention are illustrated inFIGS.1and2. Referring now toFIG.1, there is illustrated protected particle1that is formed of a base particle3and an outer coating4that is coated on the outer surface of base particle3. Base particle3includes a hollow cavity6. The thickness of the outer coating is illustrated as being greater than the thickness of the shell of the base particle; however, this is not required. As can be appreciated, the base particle can be absent hollow cavity6. As can also be appreciated, the base particle can optionally include more than one cavity. The hollow cavity can be filled with one or more gasses; however, this is not required. The pressure inside the hollow cavity can be controlled; however, this is not required. In one non-limiting arrangement, the pressure in the hollow cavity can be 0-20000 psi (and all values and ranges therebetween). In one particular configuration, the pressure in the hollow cavity is about 0-1000 psi, and typically about 0-100 psi, and more typically about 10-20 psi (e.g., 14.7 psi). When a gas is included in the hollow cavity, the type of gas is non-limiting (e.g., air, nitrogen, oxygen, etc.). The base particle can be formed of a variety of materials such as, but not limited to, glass, ceramic, or polymer. In one non-limiting configuration, the base particle is a hollow sphere formed of a glass material such as, but not limited to, borosilicate or soda-lime silicate spheres. In another non-limiting configuration, the base particle is formed of degradable sodium silicate which may or may not include a hollow cavity. The size or diameter of the base particle is generally about 10 μm-100 mm (and all values and ranges therebetween), and typically from about 30 μm-1 mm. In one non-limiting configuration, the size or diameter of the base particle is about 30-990 μm and the shape of the base particle is generally spherical. The crush strength of the base particle is generally 100-19000 psi (and all values and ranges therebetween). The outer coating is generally formed of a material that is formulated to degrade by one or more mechanisms such as, but not limited to, hydrolysis, temperature softening, dissolution, and/or an oxidation/reduction reaction (such as the oxidative dissolution of dissolvable magnesium alloys, dissolvable aluminum alloys, calcium, magnesium, dissolvable magnesium-nickel alloys, or other dissolvable metals or dissolvable metal alloys). Non-limiting examples of dissolvable metal materials that can be used are disclosed in U.S. Pat. No. 9,757,796 and US 2015/0299838, which are incorporated herein by reference. In one non-limiting configuration, the outer coating includes one or more polymers susceptible to hydrolysis, temperature-induced softening and/or temperature-induced dissolution. Non-limiting examples of polymers that can partially or fully form the outer coating include, but are not limited, to polyvinylalcohols, polycarbohydrates, polycarbonate, polylactic acid, polyglycholic acid, polyamines, polyesters, polyether, polyamine, polyacetal, polyvinyl, polyurethane, epoxy, polysiloxane, polycarbosilane, polysilane, and polysulfone and their mixtures or copolymers thereof. The thickness of the outer coating generally is 2 μm-100 mm (and all values and ranges therebetween), and typically 2 μm-60 mm. The outer coating can be applied to the base particle by any number of techniques such as, but not limited to, dipping, fluidized bed spray coating, chemical vapor deposition, suspension deposition, emulsion deposition, tumbling and vibratory bed spray coatings. Referring now toFIG.2, there is illustrated a protected particle2that is formed of a plurality of base particles3that are held together by a matrix material5. Matrix material5can be formed of the same material as outer coating4as discussed with reference toFIG.1. Likewise the base particle3can be the same as the base particle as discussed with reference toFIG.1. The volumetric ratio of the base particle to the matrix material in the protected particle 0.01-100:1 (and all values and ranges therebetween), and typically 0.01-0.5:1. The size of the protected particles is generally greater than 10 μm and typically less than about 200 mm (and all values and ranges therebetween). The protected particle is configured to survive its delivery to the desired location in the well or formation. The use of the outer coating or matrix material increases the resistance of the base particle to fracturing or crushing by the formation's hydrostatic pressure. The outer coating or matrix material is formulated to degrade over time in the well or formation, thereby resulting in the eventual fracturing or crushing of the base particle. As such, the outer coating or matrix material is formulated to delay the fracturing or crushing of the base particle until the protected particle has been placed within the well or formation. Generally, the protected particle is fed into the well or formation with a proppant; however, this is not required. The fracturing or crushing of the base particle results in the creations of an acoustic signal or emission that can be detected for use in mapping the well or formation. The base particles that are used in the protected particle are designed to have a crush strength that is less than the desired formation to be mapped. For example, if a location in a well to be mapped has a pressure of 6,000 psi, a base particle should be selected to have a crush strength of less than 6000 psi (e.g., base particle having a crush strength of 4,000 psi or less, etc.). Generally, the crush strength of the base particle is at least 100 psi less than the pressure in the well or formation to be mapped, typically at least 500 psi less than the pressure in the well or formation to be mapped, and more typically at least 750 psi less than the pressure in the well or formation to be mapped. If the crush strength of the base particle to too close to or greater than the pressure in the well or formation to be mapped, the base particle may not or will not fracture or crush, this not create the acoustic signal or emission to be used to map the well or formation. It has been found that the frequency of the generated acoustic sound or emission caused by the fracturing or crushing of the base particle is dependent on the size of the base particle and the difference in pressure between the hollow base particle's interior pressure and the formation pressure. Generally, the frequency of the generated acoustic sound or emission caused by the fracturing or crushing of the base particle is in the range of 1-10,000 Hz (and all values and ranges therebetween), and more typically from about 1-1,000 Hz. To generate such frequencies, 1) the size of the base particle is generally about 10 μm to 100 mm (and all values and ranges therebetween) in size or diameter, and typically about 30 μm to 1 mm in size or diameter, and 2) the interior pressure in the hollow cavity of the base particle is about 10 psi to 19,000 psi (and all values and ranges therebetween). Controlling the microseismic emission or signal frequency by internal pressure modification in the base particle changes the differential pressure between the hollow cavity in the base particle and the exterior well pressure; thus, the frequency of the emission or signal caused by the fracturing or crushing of the base particle can be tailored. The following equation can be used to calculate the frequency of the emission or signal caused by the fracturing or crushing of the base particle in the well or formation. ωo=1Ro3γpoρEquation1 Where ωois the resonant frequency ρ is the density of the liquid Rois the average size of the resonating balloon and Pois the average pressure By using the ideal gas law P1V1=P2V2Rocan be found by Ro=PgRi3Pl3Equation2 Where Pgis the pressure inside the balloon and P1is the pressure of the surrounding fluid at burst. From these two equations, a trend for resonant frequency vs. size and pressure can be obtained. The protected particle includes a degradable outer coating or matrix material to increase the resistance of the base particle to being fractured or crushed by the formation pressure until the protected particle has been delivered to a desired location in the well or formation. The outer coating or matrix material is thus formulated to provide temporarily protection to the base particle so that it may be delivered to the formation fractures with the proppant. The outer coating or matrix material is formulated to degrade and thus fracture or crush the base particles, creating an acoustic signal or emission that can be detected and used to map the well or formation. Common subterranean well formation conditions can range in load stress pressures of 2,000-20,000 psi, temperatures ranging from about 30-200° C., and include ionic solutions at pH from about 2-12 (the pH typically due to fracturing fluids). Therefore, the outer coating or matrix material can be selected and coating thickness selected to 1) provide crush and/or fracture protection to the base particle as the protected particle is inserted into the formation so that the base particle is not fractured or crushed prior to the protected particle being pumped, inserted or otherwise positioned in the desired location in the formation, and 2) sufficiently degrade during a certain period of time to fracture or crush the base particles and emit an acoustic signal or emission. The use of the outer coating or matrix material enables the protected particle to be pumped into a formation and placed in a desired location in the formation without premature signal emission (e.g., the base particle is not prematurely fractured or crushed prior to being pumped or otherwise placed in the desired location in the formation), and the outer coating or matrix material have a short enough degradation duration (e.g., less than 420 hours, etc.) to fracture or crush the base particle and to create an acoustic signal or emission that can be detected during the monitoring of the formation in a time efficient period. The degrading of the outer coating or matrix material can be by hydrolysis, temperature softening point/dissolution, or by other oxidation/reduction chemistries (e.g., oxidative dissolution of dissolvable magnesium alloys, etc.). As such, the selection of the material used for the outer coating or matrix material is dependent on the formation's conditions and needs to match the temperature and chemical interaction for degradation to take place in a timely manner. For example, in a typical subterranean well formation, the conditions encountered can be 90° C. with formation load stress pressure at 8,000 psi, and the pumping solution in the formation can be 2 wt. % KCl at a pH of 7. For such subterranean well formation conditions, one polymer for the outer coating or matrix material can be poly(lactic-co-glycolic acid) (PLGA), a co-polyester susceptible to degradation by hydrolysis at temperatures of 80-90° C. over a period of 12-24 hours. In more extreme subterranean well formation conditions (e.g., higher temperatures and pressures), other polymers can be used, such as polyamides or polyaryls which will degrade over a period of 6-24 hours. The thickness of the outer coating or thickness of the matrix material about the base particle, in combination with the type of material of the outer coating or matrix material, is selected to provide the desired fracture or crush protection to the base particle for a sufficient period of time to enable the protected particle to be inserted, pumped or other positioned in the desired location in the formation. The coating thickness of the outer coating or composite ratio of the matrix material to the base particles is dependent on 1) the type of material used for the outer coating or matrix material, 2) the material used to form the base particle, 3) the thickness of the shell of the base particle when the base particle includes one or more cavities, 4) the size of the base particle, 5) the crush strength of the base particle, 6) the formation pressure where the protected particle is to be located, 7) the temperature in the formation in which the protected particle is to be located, and 8) the composition and pH of the fluid in the formation in which the protected particle is to be located. Generally, the volumetric increase from the base particle to the protected particle due to the addition of the outer coating to the base particle is about 0.01-10,000% (and all values and ranges therebetween). For example, in one non-limiting embodiment of the present invention, a 40 μm hollow sphere particle having an inherent crush strength of 4,000 psi includes a polymer outer coating of 60 μm to that the protected particle can be exposed to pressures of 8,000 psi without resulting in the fracturing or crushing of the base particle. In this non-limiting embodiment, the volumetric increase from the base particle to the protected particle due to the coating of the polymer material on the outer surface of the base particle is about 1563%. The outer coating or matrix material can optionally include additives for the purpose of further improving the crush resistance of the protected particle, controlling degradation time of the outer coating or matrix material, and/or adjusting the density of the protected particle so that it can be properly pumped into a formation. The size of the additives are generally less than 100 μm, and typically less than 1 μm. Non-limiting additives for improving crush resistance include, but are not limited to, carbon nanotubes, carbon black, and nanosilica. Such additives (when used) constitute about 0.001-10 vol. % of the outer coating or matrix material (and all values and ranges therebetween). When such reinforcing or crush strength enhancement additives are used, such use of the additives increases the crush strength of the protected particle by 5-20,000% (and all values ad ranges therebetween), and typically about 10-5000%, and more typically about 10%-1000%. Non-limiting additives for controlling degradation time of the outer coating or matrix material include, but are not limited to, calcium, magnesium, calcium oxide, magnesium oxide, and super absorbent polymers or mixtures thereof. The size of the additives is generally less than 1000 μm, and typically less than 100 μm. Such additives (when used) constitute about 0.001-30 vol. % of the outer coating or matrix material (and all values and ranges therebetween). When such additives to control degradation time are used, such use of the additives typically reduces the time of degradation of the outer coating or matrix material by 5-5000%, and typically by 10-500%, and more typically by 10-100%. Non-limiting additives for adjusting the density of the outer coating or matrix material are materials having a density of at least 1.7 g/cc, typically at least 5 g/cc, and more typically at least 6.5 g/cc. Non-limiting examples of additives that can be used to adjust density include, but are not limited to, nano- and micro-powders of one or more high density metals (e.g., iron, copper, lead, steel, tungsten, etc.). Such additives (when used) constitute about 0.001-10 vol. % of the outer coating or matrix material (and all values and ranges therebetween). The size of the additives are generally less than 100 μm, and typically less than 1 μm. When such additives to adjust density are used, such use of the additives typically increase the density of the protected particle by 5-1000%, and typically by 5-100%, and more typically by 5-50%. When the protected particle is to be pumped into a formation with a proppant, the size of the protected particle to the proppant is generally similar. In one non-limiting embodiment, the size ratio of the protected particle to the proppant is generally about 0.8-1.4:1, and typically about 0.9-1.1:1. Also, the density of the protected particle to the proppant is similar when the protected particle is to be pumped into a formation with a proppant. In one non-limiting embodiment, the density ratio of the protected particle to the proppant is generally about 0.8-1.4:1, and typically about 0.9-1.1:1. As such, the size and density of the protected particle can be selected to match or closely match proppant density and size so that the protected particle can replicate the pumping and placement performance of the proppant so as to match placement of the proppant within the fractures of the formation. When the protected particle is to be pumped into a formation with a proppant, the protected particle is generally added to the proppant slurry such that there is more proppant in the slurry than protected particles. In one non-limiting embodiment, the volume ratio of the protected particle to the proppant in the slurry that is pumped or otherwise inserted into the formation is about 0.00001-0.1:1 (and all values and ranges therebetween), and typically 0.0001-0.05:1, and more typically 0.0001-0.01:1. The following are non-limiting specific examples of protected particles in accordance with the present invention: EXAMPLE 1 A protected particle was formed of a base particle having an average diameter of 30 μm. The base particle is a hollow sphere having a shell thickness of 1 μm. The interior pressure in the hollow cavity of the base particle is 14.7 psi. The density of the base particle is 0.38 g/cc and the crush strength of the base particle is 2,000 psi. The outer surface of the base particle was coated with a hydrolysable polyamine by spray coating deposition. Two different batches of protected particles were formed wherein the first batch had an outer coating thickness of 10 nm and the second batch has an outer coating thickness of 100 nm. The crush strength of both batches of protected particles exceeded 2,000 psi. The two batches of protected particles were inserted into a well formation and the fracturing or crushing of the base particle resulted in the creation of an acoustic sound or emission at a frequency of 100-20,000 Hz, and the timing of the creation of the acoustic sound or emission from the two batches of protected particles was different due to the different coating thicknesses on the two batches of protected particles. The protected particles having an outer coating thickness of 10 nm resulted in the creation of the acoustic sound or emission about 10 hours after the protected particles were pumped into the well formation. The protected particles having an outer coating thickness of 100 nm resulted in the creation of the acoustic sound or emission about 400 hours after the protected particles were pumped into the well formation. EXAMPLE 2 A protected particle was formed of a base particle having an average diameter of 100 μm. The base particle is a hollow sphere having a shell thickness of 3 μm. The interior pressure in the hollow cavity of the base particle is 14.7 psi. The density of the base particle is 0.24 g/cc and the crush strength of the base particle is 1,500 psi. The outer surface of the base particle was coated with a polyvinylalcohol coating that includes 5 wt. % fumed silica nanoparticles. The fumed silica nanoparticles were added to increase the crush strength of the protected particle. The outer coating thickness was 60 nm. The resulting protected particle has a crush strength of over 6,000 psi. The protected particle was configured to be pumpable into a formation with a proppant. EXAMPLE 3 A protected particle was formed of a base particle having an average diameter of 100 μm. The base particle is a hollow sphere having a shell thickness of 3 μm. The interior pressure in the hollow cavity of the base particle is 14.7 psi. The density of the base particle is 0.24 g/cc and the crush strength of the base particle is 1,500 psi. The outer surface of the base particle was coated with a polyvinylalcohol coating. The outer coating thickness was 60 nm. The resulting protected particle has a crush strength of about 4,000 psi. The protected particle was configured to be pumpable into a formation with a proppant. As is evident from Examples 2 and 3, the addition of additives to the outer coating can be used to change the crush strength of the protected particle. EXAMPLE 4 A protected particle was formed of a base particle having an average diameter of 100 μm. The base particle is a hollow sphere having a shell thickness of 3 μm. The interior pressure in the hollow cavity of the base particle is 14.7 psi. The density of the base particle is 0.24 g/cc and the crush strength of the base particle is 1,500 psi. The outer surface of the base particle was coated with a poly(lactic-co-glycolic acid) (PLGA) that included 5 wt. % CaO. The CaO was added to the outer coating to increase the rate of degradation of the outer coating in the well formation. The resulting protected particle has a crush strength of over 6,000 psi. The protected particle was configured to be pumpable into a formation with a proppant. The protected particles in the well formation began to create acoustic sounds or emissions due to the fracturing or crushing of the base particle about 7 hours after the protected particles were pumped into the well formation and the creation of the acoustic sounds or emissions continued for up to 2 hours thereafter. EXAMPLE 5 A protected particle was formed of a base particle having an average diameter of 100 μm. The base particle is a hollow sphere having a shell thickness of 3 μm. The interior pressure in the hollow cavity of the base particle is 14.7 psi. The density of the base particle is 0.24 g/cc and the crush strength of the base particle is 1,500 psi. The outer surface of the base particle was coated with a poly(lactic-co-glycolic acid) (PLGA). The resulting protected particle has a crush strength of over 6,000 psi. The protected particle was configured to be pumpable into a formation with a proppant. The protected particles in the well formation began to create acoustic sounds or emissions due to the fracturing or crushing of the base particle about 12 hours after the protected particles were pumped into the well formation and the creation of the acoustic sounds or emissions continued for up to 6 hours thereafter. As is evident from Examples 4 and 5, the addition of additives to the outer coating can be used to change the degradation time of the outer coating of the protected particle. EXAMPLE 6 A protected particle was formed of a plurality of base particles having an average diameter of 100 μm. The base particle is a hollow sphere having a shell thickness of 1.4 μm. The interior pressure in the hollow cavity of the base particle is 14.7 psi. The density of the base particle is 0.1 g/cc. The plurality of base particles was mixed with a matrix material formed of poly(lactic-co-glycolic acid) (PLGA) and 10 wt. % micron tungsten powder. The micron tungsten powder was added to the PLGA to increase the density of the protected particle. The micron tungsten powder was formed from a filament of tungsten having a 1 mm diameter. The filament was chopped into the desired size. The base particles constituted 30 vol. % of the protected particle. The protected particle was formed through melt mixing extrusion of the base particles with the matrix material. The protected particle had a density of about 2.8 g/cc. The protected particles were added to a proppant slurry and constituted about 0.1 wt. % of the proppant slurry. The proppant slurry with the protected particles was pumped into the fracturing zones of a well. The matrix material of the protected particles degraded by hydrolysis and the rate of degradation only increased to an appreciable rate once the protected particles encountered the higher temperatures within the deep well's fractures (around 60-100° C.) at pH of 6-8. In the higher temperature environment (60-100° C.) and exposed to fluids at a pH of 6-8, the matrix material degraded within 24 hours thereby releasing the base particles from the protected particle, thus resulting in the fracturing and crushing of the base particles. The fracturing or crushing of the base particles resulted in acoustic sounds or emissions being created at a certain frequency which were detected by sensor arrays. The recorded signals from the cumulative sensor arrays were then interpreted with modeling software to identify source locations of the signals, and such information was then used to mapping out proppant placement in the well, and to determine where successful fracturing had occurred in the well. EXAMPLE 7 A protected particle was formed of a base particle having an average diameter of 40 μm. The base particle is a hollow sphere having a shell thickness of 1 μm. The interior pressure in the hollow cavity of the base particle is 14.7 psi. The density of the base particle is 0.38 g/cc and the crush strength of the base particle is 1,500 psi. The outer surface of the base particle was coated with a PLGA by suspension deposition. The coating thickness was 60 μm. The protected particle had a crush strength of about 8000 psi. The protected particles were subjected to well conditions of 30,000 ppm brine solution at a pH of 7.5, a temperature of 90° C., and under 6,000 psi hydrostatic pressure. After about 12 hours and over the period of 2 hours thereafter, the base particles were fractured or crushed. The acoustic sound or emission created by the fractured or crushed base particles had a traceable harmonic resonant frequency peak at 1,500 Hz. EXAMPLE 8 A protected particle was formed of a base particle having an average diameter of 20 μm. The base particle is a hollow sphere having a shell thickness of 1 μm. The interior pressure in the hollow cavity of the base particle is 14.7 psi. The density of the base particle is 0.38 g/cc and the crush strength of the base particle is 1,500 psi. The outer surface of the base particle was coated with a PLGA by suspension deposition. The coating thickness was 18 μm. The protected particle had a crush strength of about 8000 psi. The protected particles were subjected to well conditions of 30,000 ppm brine solution at a pH of 7.5, a temperature of 90° C., and under 6,000 psi hydrostatic pressure. After about 12 hours and over the period of 2 hours thereafter, the base particles were fractured or crushed. The acoustic sound or emission created by the fractured or crushed base particles had a traceable harmonic resonant frequency peak at 3,000 Hz. As is evident from Examples 7 and 8, the protected particle can be tailored by using different sized base particles to create a certain frequency or range of frequencies when the base particle fractures or crushes. EXAMPLE 9 A protected particle was formed of a base particle having an average diameter of 40 μm. The base particle is a hollow sphere having a shell thickness of 1 μm. The interior pressure in the hollow cavity of the base particle is 14.7 psi. The density of the base particle is 0.38 g/cc. The outer surface of the base particle was coated with a PVA by suspension deposition. The coating thickness was 68 μm. The protected particle had a crush strength of about 8000 psi. The protected particles were subjected to well conditions of 10,000 ppm brine solution at a pH of 8, a temperature of 80° C., and under 6,000 psi hydrostatic pressure. After about 36 hours and over the period of 72 hours thereafter, the base particles were fractured or crushed. The acoustic sound or emission created by the fractured or crushed base particles had a traceable harmonic resonant frequency peak at 1,500 Hz. EXAMPLE 10 A protected particle was formed of a base particle having an average diameter of 40 μm. The base particle is a hollow sphere having a shell thickness of 1 μm. The interior pressure in the hollow cavity of the base particle is 1000 psi. The density of the base particle is 0.39 g/cc. The outer surface of the base particle was coated with a PVA by suspension deposition. The coating thickness was 68 μm. The protected particle had a crush strength of about 8000 psi. The protected particles were subjected to well conditions of 10,000 ppm brine solution at a pH of 8, a temperature of 80° C., and under 6,000 psi hydrostatic pressure. After about 36 hours and over the period of 72 hours thereafter, the base particles were fractured or crushed. The acoustic sound or emission created by the fractured or crushed base particles had a traceable harmonic resonant frequency peak at 600 Hz. As is evident from Examples 9 and 10, the protected particle can be tailored by using certain pressures in the hollow cavity of the base particle to create a certain frequency or range of frequencies when the base particle fractures or crushes. EXAMPLE 11 A protected particle was formed of a base particle having an average diameter of 40 μm. The base particle is a hollow sphere having a shell thickness of 1 μm. The interior pressure in the hollow cavity of the base particle is 14.7 psi. The density of the base particle is 0.38 g/cc. The outer surface of the base particle was coated with a PVA that included additive of nano-carbonyl iron to adjust the density of the protected particle to 1.9 g/cc. The coating was applied to the base particle by suspension deposition. The coating thickness was 60 μm. The protected particle had a crush strength of about 8000 psi. The protected particles were subjected to well conditions to fracture or crush the base particles. The acoustic sound or emission created by the fractured or crushed base particles had a traceable harmonic resonant frequency peak at 1,500 Hz. EXAMPLE 12 A protected particle was formed of a base particle having an average diameter of 20 μm. The base particle is a hollow sphere having a shell thickness of 1 μm. The interior pressure in the hollow cavity of the base particle is 1000 psi. The density of the base particle is 0.38 g/cc. The outer surface of the base particle was coated with a PVA that included additive of nano-carbonyl iron to adjust the density of the protected particle to 2.9 g/cc. The coating was applied to the base particle by suspension deposition. The coating thickness was 60 μm. The protected particle had a crush strength of about 8000 psi. The protected particles were subjected to well conditions to fracture or crush the base particles. The acoustic sound or emission created by the fractured or crushed base particles had a traceable harmonic resonant frequency peak at 1,200 Hz. As is evident from Examples 11 and 12, the protected particle can be tailored by using certain pressures in the hollow cavity of the base particle and sizes of the base particles to create a certain frequency or range of frequencies when the base particle fractures or crushes. When two or more different types of protected particles that have been tailored to generate different frequencies or ranges of frequencies when the base particles of the two or more different protected particles are fractured or crushed, the recorded multiple frequency profile signals at the sensor arrays can be used to provide two or more separate maps of the fractures and formations in a well. Such information can be used to provide increased accuracy to the mapping of formations. EXAMPLE 13 A protected particle was formed of a base particle having an average diameter of 200 μm. The base particle is a hollow sphere having a shell thickness of 48 μm. The base particle was formed of degradable sodium silicate. The interior pressure in the hollow cavity of the base particle is 14.7 psi. The density of the base particle is 2.06 g/cc. The outer surface of the base particle was coated with a polylactic acid (PLA) by fluid bed spray coating. The coating thickness was 0.5 μm. The protected particle had a crush strength of over 12,000 psi. The protected particles were added to a proppant slurry and constituted about 0.5 wt. % of the proppant slurry. The proppant slurry with the protected particles was pumped into the fracturing zones of a well. The outer coating of PLA degraded by hydrolysis in the well and the rate of degradation only increased to an appreciable rate once the PLA encounters the higher temperatures within the deep well's fractures (around 60-100° C.), and thereafter degraded within 24 hours which exposed the readily degradable sodium silicate hollow spheres to the well pressure, thus being hydrostatically crushed. EXAMPLE 14 A protected particle was mixed with a fracturing proppant such that the protected particles constituted about 1 wt. % of the proppant slurry. The proppant slurry was then pumped into the fracturing zones in a well. The use of the protected particles increased the recordable signal from hydraulic fracture formation to a signal-to-noise ratio of 1.05. The subterranean noise was approximately 30 dB and the base recorded fracture noise was about 32 dB. The protected particle, after its controlled delay for signaling due to the fracturing or crushing of the base particles, increased the recorded fracture formation microseismic noise to a signal-to-noise ratio of 2.0, with peak frequencies recorded up to 60 dB. Such increases in signal-to-noise ratio were used to improve the accuracy in the mapping of the formations in the well. The protected particles in Examples 1-14 can be used to map well formations or other types of formations by the pumping, insertion or placement of the protected particle in the formation and then monitoring the created signal or emission from the fractured or crushed base particle after the protected particle is located in the desired location in the formation. As can be appreciated, the protected particles in accordance of the present invention can have other uses. For example, the protected particle can be used to monitor subterranean pressures through the well and across different regions in the well as illustrated in Example 15. EXAMPLE 15 A protected particle was formed of a base particle having an average diameter of 500 μm. The base particle is a hollow sphere having a shell thickness of 10 μm. The interior pressure in the hollow cavity of the base particle is 14.7 psi. The outer surface of the base particle was coated with a polyester by chemical vapor deposition. The coating thickness was 120 μm. The protected particle had a crush strength of about 7000 psi. The protected particles were subjected to well conditions to fracture or crush the base particles. The acoustic sound or emission created by the fractured or crushed base particles had a traceable harmonic resonant frequency peak at 550 Hz. The polyester coating was used because of its slow degradation rate in well formation. For this application of the protected particles, the base particle in the protected particles was to be fractured or crushed when the protected particle encountered a pressure in the formation that was greater than the crush strength of the protected particle (e.g., the crush strength of the protected particle prior to any significant degradation of the outer coating). In use, when the protected particle is pumped into the subterranean fractures of the well, the protected particle will eventually encounter a well pressure that is greater than the crush strength of the protected particle, thereby resulting in the base particle being fractured or crushed, thereby creating an acoustic signal or emission that can be detected. By using this technique, protected particles having known crush strengths can be used to map the pressures in a well formation by monitoring such certain protected particles creating an acoustic signal or emission that can be detected. As illustrated in Example 16, the frequency of the protected particle can be tailored to distinguish protected particles having different crush strengths. EXAMPLE 16 A protected particle was formed of a base particle having an average diameter of 500 μm. The base particle is a hollow sphere having a shell thickness of 10 μm. The interior pressure in the hollow cavity of the base particle is 14.7 psi. The outer surface of the base particle was coated with a polyester by chemical vapor deposition. The coating thickness was 100 μm. The protected particle had a crush strength of about 6000 psi. The protected particles were subjected to well conditions to fracture or crush the base particles. The acoustic sound or emission created by the fractured or crushed base particles had a traceable harmonic resonant frequency peak at 500 Hz. The polyester coating was used because of its slow degradation rate in well formation. For this application of the protected particles, the base particle in the protected particles was to be fractured or crushed when the protected particle encountered a pressure in the formation that was greater than the crush strength of the protected particle (e.g., the crush strength of the protected particle prior to any significant degradation of the outer coating). In use, when the protected particle is pumped into the subterranean fractures of the well, the protected particle will eventually encounter a well pressure that is greater than the crush strength of the protected particle, thereby resulting in the base particle in the protected particle being fractured or crushed, thereby creating an acoustic signal or emission that can be detected. By using this technique, protected particles having known crush strengths can be used to map the pressures in a well formation by monitoring such certain protected particles creating an acoustic signal or emission that can be detected. As can be appreciated, different types of protected particles can be used to map different pressures in a well formation. For example, the protected particles in Example 15 can be used to map when the pressure in certain locations or regions of the well formation are about 7000 psi, and the protected particles in Example 16 can be used to map when the pressures at certain locations or regions in the well formation are about 6000 psi. The different frequencies created by these two protected particles when the base particle is fractured or crushed can be used to identify which of the protected particles are fracturing or crushing in the well formation and the location in the well of such protected particles. It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained, and since certain changes may be made in the constructions set forth without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. The invention has been described with reference to preferred and alternate embodiments. Modifications and alterations will become apparent to those skilled in the art upon reading and understanding the detailed discussion of the invention provided herein. This invention is intended to include all such modifications and alterations insofar as they come within the scope of the present invention. It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention, which, as a matter of language, might be said to fall there between. The invention has been described with reference to the preferred embodiments. These and other modifications of the preferred embodiments as well as other embodiments of the invention will be obvious from the disclosure herein, whereby the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims. | 41,602 |
11859490 | DETAILED DESCRIPTION Aspects of the presently disclosed technology involve controlling one or more aspects of a fracturing operation, alone or in combination. In certain implementations, the presently disclosed technology involves rate cycling of fracturing fluid injected into a wellbore during the fracturing operation based on measurements made at a monitor well. Rate cycling is a technique in which the rate at which fracturing fluid is pumped into a well is varied throughout the fracturing operation. The cycles are controlled based on feedback from the monitor well. Generally, the flow rate may be cycled between a relatively higher flow rate to promote development and propagation of fractures within the formation and a relatively lower flow rate to release stresses induced in the formation during the high flow rate period, although many other cycles and bases for such cycles are possible. It is understood that rate cycling of fracturing fluid during a fracturing operation may provide several benefits, alone or in combination. First, rate cycling may inhibit focused growth of only a limited number of dominant fractures in an area of the wellbore being completed. Stated differently, controlled rate cycling may distribute the fracturing fluid across many fractures and grow such fractures rather than focusing the fluid to relatively fewer numbers of dominant fractures in any given stage being fractured. Second, rate cycling may initiate new fractures within the stage being completed. Thus, in a simplified example, rather than growing the dominant fracture group, several new fractures may be successively initiated and grown after a rate cycle or rate cycles. Third, rate cycling may be controlled and used to arrest breakthrough of fractures from a wellbore being completed into an adjacent wellbore. Fourth, rate cycling may facilitate fracturing operations without the need for diverters in the fracturing fluid. In effect, it is believed that rate cycling has the effect of diverting an increased proportion of fracturing fluid from dominant fractures undergoing significant propagation prior to the rate cycle into new, or smaller fractures, after the rate cycle. Fifth, rate cycling may facilitate greater production volume and greater production longevity of a fractured wellbore and possibly reduce initial completion costs. For example, it is believed that a greater number of fractures may be initiated resulting in greater production from the wellbore at less relative cost than the same wellbore fractured without the controlled rate cycling techniques described herein. Moreover, the same wellbore may be completed without particulate diverters thus providing additional cost advantages and/or production advantages relative to conventional techniques using particulate diverters. Propagation and distribution of fractures may also be controlled by varying other parameters of a fracturing operation. Such parameters may include, without limitation, fracturing fluid viscosity, proppant size, proppant concentration, fracturing fluid additive ratios, and fracturing fluid injection rate. To further promote or inhibit fracture growth and distribution, one or more of such parameters may be modified during the course of a fracturing operation in response to measurements obtained from a monitor well and. For example, if increased fracture height is desired, fracturing fluid viscosity may be increased. Conversely, if further fracture height is to be inhibited, viscosity may be reduced. As another example, if increased lateral propagation of fractures is desired, viscosity may be decreased. Conversely, if lateral propagation is to be inhibited, viscosity may be increased. The success of a fracturing operation generally depends on adequate distribution and propagation of fractures within the area of the formation around a wellbore being fractured. However, due to the remoteness of the fractures being formed it is often difficult or cost-prohibitive to accurately determine how a given fracturing operation is progressing. To control fracturing operations (e.g., by modifying fracturing operation parameters such as injection rate, viscosity, proppant size, proppant concentration, etc.) during fracturing of a wellbore being completed (referred to herein as an active well), systems and methods according to certain implementations of the present disclosure monitor pressure in an adjacent well, referred to herein as a monitor well. A portion of the monitor well is poroelastically coupleable to the active well such that a pressure response is produced in the monitor well during fracturing of the active well. For example, the monitor well may include a section spaced within 1,000 to 2,000 feet from the stage of the active well being completed and include at least one fracture, referred to herein as a monitor or transducer fracture, that extends from the monitor well toward the stage of the active well undergoing completion. Stated simply, as fluid is pumped into the active well and fractures are formed and/or propagate through the formation, the transducer fracture is compressed, thereby increasing pressure within the monitor well. More specifically, according to the principles of poroelasticity, fractures propagating from the active wellbore during fracturing induce pressure changes in the monitor well when the fractures from the active well overlap the transducer fracture of the monitor well. When this occurs, pressure in the monitor well increases relative to some baseline pressure or rate of pressure change, such as a leak off rate. Such pressure changes may be observed, for example, as an increase in pressure relative to a baseline pressure of the monitor well or a decrease in the leak off rate of the monitor well as compared to a baseline leak off rate of the monitor well obtained prior to initiating the fracturing operation in the active well. In certain implementations, characteristics of one or more of the monitor well, the active well, and the transducer fracture are used, at least in part, to characterize the pressure response of the monitor well as well as use the information to further define completion operations. For example, the geometry of the monitor well and/or the transducer fracture may be used in analyzing the pressure response caused by injecting fracturing fluid into the active well. A calibration operation may also be performed to determine characteristics of one or more of the active well, the monitor well, and the subsurface formation between the active well and the monitor well. For example, in one embodiment, a fracture formation rate of the subsurface formation may be determined. To do so, a single entry point may be made in the active well and fracturing fluid may be pumped into the active well at a known rate. When a corresponding pressure response in the monitor well is observed, the single fracture has extended from the active well to overlap the monitor well and/or a fracture of the monitor well. Accordingly, by knowing the distance between the active well and the monitor well/monitor well fracture and the rate at which fracturing fluid was provided to the active well, an approximate relationship between flow rate of fracturing fluid and fracture growth can be determined. For example, if 100 barrels of fracturing fluid cause a pressure response in a monitor well 1000 feet away from the active well, every barrel of fracturing fluid creates approximately 10 feet of fracture half-length. Changes in the pressure within the monitor well can then be used to approximate, without limitation, the location, size, direction, and similar characteristics of fractures associated with the active well and to dynamically control or inform the fracturing operation. For example, the fracturing operation may be controlled in response to changes in pressure observed within the monitor well by, without limitation, one or more of changing the flow rate of fracturing fluid provided to the active well, changing the duration for which a particular flow rate is maintained, changing the pressure of fracturing fluid provided to the active well, changing the concentration of proppants and/or density of the fracturing fluid, and controlling whether to continue or cease fracturing operations in whole or in part. Such controls may be done alone or in various possible combinations. Accordingly, pressure within the monitor well may be used to dynamically adjust parameters of the fracturing operation in response to characteristics of the subsurface formation through which the fractures extend, characteristics of the fractures, characteristics of initial perforations in the wellbore, and other sources of variability in the fracturing operation. In certain implementations, control of fracturing operations may be achieved, at least in part, by a computing system adapted to receive and process data collected from the monitor well. The computing system may be communicatively coupled to equipment for performing a fracturing operation such that the computing system may modify one or more operational parameters of the equipment in response to the received data. The logic and outputs governing control by the computing system may be maintained in a fracturing operation plan executable by the computing system. Control of the equipment may also be accomplished, in whole or in part, through manual intervention by an operator. For example, the computing system may receive data and generate an updated fracturing operation plan that may then be manually executed by an operator who activates, deactivates, or otherwise modifies operational parameters of equipment for performing the fracturing operation. The monitor well is generally capped under pressure and pressure within the monitor well is measured using, for example, gauges, or transducers located at the well head. Alternatively, downhole transducers may be installed within the monitor well and communicatively coupled to communication devices disposed at the well head. In certain implementations, a baseline leak off rate of the monitor well is obtained prior to fracturing of the active well. The gradual decrease in pressure within the monitor well over time, caused by fluid and pressure loss into the surrounding formation, is known as the leak off rate. The leak off rate is generally a function of the porosity, permeability, and pore pressure of the formation surrounding the monitor well and the baseline leak off rate corresponds to the leak off rate of the monitor well when the active well is not being fractured and often will be done prior to initiation of fracturing of the active well. During completion of the active well, the leak off rate in the monitor well is compared to the baseline leak off rate and/or one or more other observed leak off rates, with the differences being the leak off rates being used to determine when and to what extent to control the fracturing operation. While much of the discussion herein references a comparison to a leak off rate, it is also possible to compare pressure in the monitor well to a discrete pressure value, a discrete flow value or some other discrete attribute of the monitor well indicative of an induced poroelastic effect between fractures forming from the active well and the monitor well. Initial pressurization of the monitor well can be achieved in various ways. For example, the monitor well may be maintained under pressure following completion/fracturing of the monitor well. Alternatively, the monitor well may be pressurized by injecting fluid, such as water, into the monitor well. Notably, this latter approach facilitates the repurposing of dead or otherwise unused wells as monitor wells. In still other implementations, the monitor well may be a producing well. In implementations in which the monitor well is a producing well, additional steps may be taken to facilitate use of the monitor well including, without limitation, one or more of adding water or other fluids to the monitor well, installing downhole gauges, and estimating hydrostatic pressure within the well based on the fluid being produced in the monitor well. The foregoing discussion primarily described implementations of the present disclosure in which pressure changes within a monitor well result from poroelastic coupling with an active well that is being fractured and modifying fracturing operations based on such observations. In other implementations of the present disclosure, fracturing operations may be controlled, at least in part, in response to pressure changes induced in the monitor well due to direct fluid communication between the active well and the monitor well. Such direct fluid communication may occur as a result of a fracture fully extending between the active well and the monitor well, thereby enabling fracturing fluid to enter the monitor well. In such circumstances, the pressure response caused by the direct fluid communication may similarly be used to modify or otherwise control fracturing operations. In still other implementations, control of fracturing operations is achieved without the use of a separate monitor well. Instead of using a monitor well, a portion of the active well is isolated and equipped with a pressure gauge or similar device for measuring pressure within the isolated section. Similar to the previously discussed monitor well, the isolated section may also include a transducer fracture extending into the surrounding subsurface formation. When an uphole section of the well is subsequently fractured, a pressure response may be observed within the isolated section due to poroelastic coupling between the fractures extending from the uphole section and the transducer fracture extending from the isolated section. This pressure response may subsequently be used to control modify or otherwise control fracturing operations. FIG.1is a schematic diagram of an example well completion environment100for completing a fracturing operation in accordance with the present disclosure. The well completion environment100includes a subsurface formation106through which an active well120and a monitor well122extend. The active well120includes a vertical active well section102and a horizontal active well section104. Similarly, the monitor well122is also a horizontal well and includes a vertical monitor well section108and a horizontal monitor well section110. The monitor well122includes at least one transducer fracture142extending toward the active well120with the area from the tip of the transducer fracture142rearward toward the monitor well defining a poroelastic region134. The poroelastic region134corresponds to a portion of the subsurface formation106where the active well120is poroelastically coupleable with the monitor well122. Poroelastic coupling, as used herein, refers to a physical phenomenon in which two regions within or adjacent to a porous material are arranged such that when a force or pressure is applied to one region, the force or pressure is transmitted, at least in part, to the second region as a result of the poroelastic properties of the material. Accordingly, the poroelastic region134corresponds to a region within the subsurface formation106and adjacent a fracture of the monitor well122in which the active well120and the monitor well122may be poroelastically coupled to each other. As described below in more detail, such poroelastic coupling occurs when a fracture formed adjacent the active well120propagates and overlaps a fracture of the monitor well122, referred to herein as a transducer fracture142, enabling observations of pressure or other response within the monitor well122during fracturing of the active well120. Hence, the monitor well122includes at least one transducer fracture142extending toward the active well120such that a region from the tip of the transducer fracture142rearward toward the monitor well122defines the poroelastic region134. The active well120includes an active wellhead124disposed at a surface130. Similarly, the monitor well122includes a monitor wellhead126at the surface130. The monitor wellhead126further includes a pressure gauge144for measuring pressure within the monitor well122. In certain implementations, instead of or in addition to pressure gauge144, the monitor wellhead126includes a pressure transducer configured to transmit pressure data from the monitor wellhead126to a computing system150. In the well completion environment100, the computing system150is communicatively coupled to a pumping system132(illustrated inFIG.1as including a pump truck135) such that the computing system150can transmit pressure data, control signals, and other data to the pumping system132to dynamically adjust parameters of the fracturing operation based on pressure measurements received from the monitor wellhead126. The pumping system132generally provides fracturing fluid into the active well120and, in certain implementations, may include additional equipment for modifying characteristics of the fracturing fluid and/or the manner in which the fracturing fluid is injected into the active well120. Such equipment may be used, for example, to add or change a proppant or other additive of the fracturing fluid in order to modify, among other things, the viscosity, proppant concentration, proppant size, or other aspects of the fracturing fluid. Accordingly, such equipment may include, without limitation, one or more of tanks, pumps, filters, and associated control systems. The computing system150may include one or more local or remote computing devices configured to receive and analyze the pressure data to facilitate control of the fracturing operation. The computing system150may be a single computing device communicatively coupled to components of the well completion environment100, or forming a part of the well completion environment100, or may include multiple, separate computing devices networked or otherwise coupled together. In the latter case, the computing system150may be distributed such that some computing devices are located locally at the well site while others are maintained remotely. In certain implementations, for example, the computing system150is located locally at the well site in a control room, server module, or similar structure. In other implementations, the computing system is a remote server that is located off-site and that may be further configured to control fracturing operations for multiple well sites. In still other implementations, the computing system150, in whole or in part, is integrated into other components of the well completion environment100. For example, the computing system150may be integrated into one or more of the pumping system132, the active wellhead124, and the monitor wellhead126. Pressure gauge144is configured to measure pressure within the monitor well126during fracturing of the active well120. As shown in the well completion environment100, pressure gauge144is coupled to the monitor wellhead126. Pressure gauge144is communicatively coupled to the computing system150, such as by a pressure transmitter. In alternative implementations, pressure gauge144may be replaced or supplemented with other pressure measurement devices. For example, in certain implementations, pressure may be measured using, without limitation, one or more digital and/or analog pressure gauges coupled to the monitor wellhead126, downhole pressure transmitters disposed within the monitor well124, and pressure sensors incorporated into one or more flow meters (such as differential pressure flow meters). The pressure measurement device may be permanently fixed into casing, coiled tubing, or other structure disposed within the active well120or may be temporarily inserted into the active well120using, for example, a wireline or other conveyance. In still other implementations, other measuring devices may be used to indirectly determine pressure within the monitor well120, such as by measuring a temperature within the monitor well120that is then used to determine pressure within the monitor well120. Well completion environment100is depicted after perforation but before fracturing of the active well120. Accordingly, horizontal active well section104includes a plurality of perforations138extending into subsurface formation106and, more specifically, towards the poroelastic region134. The entire formation surrounding the wellbores may demonstrate poroelasticity. The term poroelastic region is meant to refer to the area, typically between the wellbores, where a propagating fracture from the active wellbore may overlap a fracture (e.g., the transducer fracture142) extending from the monitor well122and produce a poroelastic response in the monitor well122. The perforations138are formed during completion of the active well120to facilitate introduction of fracturing fluid into the subsurface formation106adjacent the horizontal active well section104. For example, in certain completion methods, casing is installed within the well and a perforating gun is positioned within the active well120adjacent the portion of the subsurface formation106to be fractured. The perforating gun includes shaped charges that, when detonated, create perforations that extend through the casing and into the adjacent formation, thereby creating an initial fluid path from the subsurface formation106into the active well120. During fracturing, fracturing fluid is pumped into the active well120and the fluid passes through the perforations138under high pressures and rate. As pressure increases, the fracturing fluid injection rate increases through the perforations138, forming fractures that propagate through the subsurface formation106, thereby increasing the size and quantity of fluid paths between the subsurface formation106and the active well120. In contrast to the active well120, the monitor well122is previously completed and includes one or more fractures140. It is also possible that the monitor well122intersects one or more preexisting fractures, which may serve as transducer fractures. Hence, the monitor well122includes at least one transducer fracture142extending toward the active well120with the area from the tip of the transducer fracture142rearward toward the monitor well being the poroelastic region134. Alternative fracturing methods may also be used in conjunction with the systems and methods disclosed herein. For example, in certain implementations, the fracturing operation is an open-hole fracturing operation. In contrast to methods in which a casing is installed and then perforated prior to fracturing, open-hole fracturing is performed on an unlined section of the wellbore. Generally, open-hole fracturing involves isolating sections of the uncased wellbore using packers or similar sealing elements. Sliding sleeves or similar valve mechanisms disposed between the packers are then opened to permit pumping of the fracturing fluid into the surrounding formation. As pressure within the formation increases, fractures are formed and propagated. In multi-stage wells, this process is repeated for each stage moving up the wellbore. The active wellhead124is coupled to a pumping system132for pumping fracturing fluid into the active well120. In the well completion environment100, for example, the pumping system132includes a pump truck135coupled to the active wellhead124. The pump truck135includes a tank or other means for storing the fracturing fluid and a pump coupleable to the active wellhead124for pumping fluid into the active well120. In other embodiments, the pumping system132includes other equipment for providing fracturing fluid to the active well120including, without limitation, storage tanks or other vessels and one or more additional pumps. The pumping system132may further include equipment configured to modify the fracturing fluid, for example, by adding one or more additives, such as proppants, to the fracturing fluid. The pumping system132may also include equipment, such as filters, to treat and recycle fracturing fluid. As shown in the implementation ofFIG.1, the pumping system132, and more particularly pump truck135, is communicatively coupled to the computing system150. Accordingly, the pump truck135can receive sensor data, control signals, or other data from the computing system150, including data configured to be used in control and monitoring of an ongoing fracturing operation. During fracturing, fracturing fluid is pumped by the pumping system132into the active well120. The fracturing fluid enters the subsurface formation106through the perforations138. As the fracturing fluid continues to enter the subsurface formation106, pressure within a portion of the subsurface formation106adjacent the perforations138increases, leading to the formation and propagation of fractures within the subsurface formation106. As the fractures from the active well120propagate into the poroelastic region134, the active well120and the monitor well122become poroelastically coupled. More specifically, one or more dominant fractures (such as the dominant fracture212illustrated inFIG.2A) from active well120extend into the poroelastic region134and overlaps the transducer fracture142of the monitor well122. As a result, the active well120and the monitor well122become poroelastically coupled such that forces or pressures applied to the subsurface formation106by injection of the fracturing fluid into the active well120are transmitted through the poroelastic region134and applied to the transducer fracture142of the monitor well122. The transmitted forces or pressures create a pressure response in the monitor well122that may be measured using pressure gauge144or other pressure measurement device and used to dynamically adjust the fracturing operation. For example, in one embodiment, measurements from pressure gauge144are used to determine when to initiate a rate cycle (or change to one or more other fracturing operation parameters) during the fracturing operation. In alternative implementations of the present disclosure, one or both of the active well120and the monitor well122are vertical wells. Moreover, implementations of the present disclosure may include more than one active well and/or more than one monitor well. For example, multiple monitor wells may be used to monitor fracturing of one active well. In addition to or instead of poroelastic coupling of the active well120and the monitor well122, the active well120and the monitor well122may be directly coupled such that they are in direct fluid communication with each other. For example, during the fracturing operation, a fracture extending form the active well120may intersect one or more of the transducer fracture142, a different fracture of the monitor well122, and the monitor well122itself. In such instances, pumping of fracturing fluid into the active well120will induce a pressure response in the monitor well122that may be used to actively control the corresponding fracturing operation. Notably, the active well120and the monitor well122may be both poroelastically coupled and in direct fluid communication with each other such that the pressure response observed in the monitor well122is a result of both poroelastic coupling and direct coupling. Additionally, depending on the porosity of the formation and other factors, pumping fluid into the active well120may generate some pressure response in the monitor well122without poroelastic coupling or direct fluid communication. For example, after pumping of fracturing fluid for a particular stage has been completed, the recently injected fracturing fluid may leak off into the monitor well122creating a pressure response within the monitor well122independent of poroelastic coupling. As noted above, well completion environment100includes one active well120and one monitor well122. In alternative implementations, well completion environments in accordance with this disclosure may include more than one of either active wells or monitor wells. For example, in certain implementations, multiple monitor wells may monitor fracture growth in one or more active wells. Because each monitor well has a different location and orientation, each monitor well would therefore identify fracture growth in different directions. Similarly, one monitor well may be used to monitor fracture growth in multiple active wells. For example, one active well may be positioned between two or more active wells such that the monitor well is poroelastically coupleable and provides a pressure response when fracturing any of the active wells. FIG.2Ais an example graph200illustrating monitor well pressure and fracturing fluid flow rate over time during a fracturing operation according to the present disclosure. For explanatory purposes, the following description ofFIG.2Areferences components of the well completion environment100ofFIG.1. Accordingly, the graph200includes a pressure line202(shown as a solid line) corresponding to pressure readings obtained from a pressure gauge144or transducer configured to measure pressure within the active well122and a flow rate line204(shown as a periodic dashed line) corresponding to the flow rate of fracturing fluid provided by a pumping system132into the active well120during the fracturing operation.FIG.2Afurther includes a set of schematic illustrations206A-H. The illustrations206A-H depict, during various stages of the fracturing operation, each of the horizontal active well section104, the horizontal monitor well section110, the poroelastic region134disposed between the active well120and the monitor well and a plane210(to not unnecessarily obscure the illustrations not every feature is labeled in each illustration). The plane210corresponds to the point in the poroelastic region134beyond which the active well120and the monitor well122become poroelastically coupled. Accordingly, as a fracture from the active well120propagates beyond the plane210, a pressure response becomes observable within the monitor well122due to poroelastic coupling. For purposes of simplicity, only the transducer fracture142of the monitor well122is depicted in illustrations206A-H. The fracturing operation depicted in the graph200ofFIG.2Agenerally illustrates an implementation of systems and methods described herein for controlling rate cycling of a fracturing operation. More specifically, the fracturing operation controls rate cycling of a fracturing operation in the active well120based on pressure changes (and/or lack of pressure changes) observed in the monitor well122, where the changes in the rate of pressure change are due to poroelastic coupling of the active well120and the monitor well122. As previously discussed, rate cycling generally involves pumping fracturing fluid into a subsurface formation at other than a steady flow rate. Accordingly, the pressure changes observed in the monitor well122are used to trigger various changes in the flow rate of fracturing fluid pumped into the active well120. In other implementations, changes in pressure within the monitor well122can be used to control other parameters of the fracturing operation alone or in combination with parameters relating to rate cycling. For example, and without limitation, changes in pressure within the monitor well122can be used to control one or more fracturing operation parameters including, without limitation, the pressure at which fracturing fluid is pumped into the active well122, the concentration of proppants or additives within the fracturing fluid, the density of the fracturing fluid, and the type of fracturing fluid used. In many cases, such changes may further be coordinated with rate cycling but may not occur at the same times as rate is changed. For example, one or more of the fluid pressure, proppant/additive concentration, fluid density, and type of fracturing fluid may be changed as the fluid flow rate is increased or decreased at the beginning or end of a rate cycle or at any time after the target rate for the rate cycle is achieved. Referring now in more detail toFIG.2A, during time interval t0to t1, a baseline leak off rate for monitor well122is obtained. The baseline leak off rate is the rate at which pressure within monitor well122declines absent influence from the active well120. More particularly, the baseline leak off rate is the rate at which pressure reduces within monitor well122absent pressure effects attributable to pumping fracturing fluid into the active well120due to poroelastic coupling of the active well120and the monitor well122. The baseline rate is indicated in the graph200by a baseline slope220. After a baseline leak off rate is established, fracturing fluid is pumped into the active well122. More specifically, during interval t1to t2, the pumping system132is activated and the flow rate of fracturing fluid into the active well120is increased until a first flow rate is reached at time t2. As illustrated in the transition between schematic illustration206A and206B, the introduction of fracturing fluid into active well120induces propagation of fractures originating from the active well120, including the formation of a first dominant fracture212. As fluid is pumped into the active well120at an increasing flow rate, the first dominant fracture212begins to enter the poroelastic region134by crossing the plane210indicating when poroelastic coupling occurs. During this ramp up period, a pressure increase is observed within the monitor well122because of the poroelastic coupling between the first dominant fracture212and the transducer fracture142. This pressure increase is illustrated in the graph200as a reduction in slope of the pressure line between times t1and t2. The rate of pressure change during time interval t1to t2, illustrated by a first slope222, is reduced as compared to the baseline slope220observed during time interval t0to t1. Notably, the first slope222is still negative, indicating that pressure within the monitor well122is still declining despite the pressure effects caused by the fracturing fluid. However, the rate at which the pressure is declining during time interval t1to t2is less than that observed during time t0to t1. At time t2(and as shown in illustration206C) the first flow rate is reached and the first dominant fracture212continues to propagate and further overlap the transducer fracture142. As indicated in time interval t2to t3, achieving the first flow rate and the corresponding progression of the first dominant fracture212into the poroelastic region134results in an even greater increase of pressure within monitor well122as compared to the pressure increase observed during time interval t1to t2. In the example provided, the pressure increase experienced during time interval t2to t3is significant enough to cause the pressure within monitor well122to increase between time t2and t3as indicated by a second, positive slope224. At time t3, a rate cycle is initiated by reducing the fracturing fluid flow rate provided by the pumping system132. The reduction in fracturing fluid flow rate induces a relaxation of the poroelastic region134and a corresponding reduction in pressure within the monitor well122. Accordingly, the leak off rate (i.e., the change in pressure of the monitor well122over time) during time interval t3to t4substantially returns to the baseline leak off rate measured during time interval t0to t1. As shown in illustration206D, relaxation of the poroelastic region134may further result in closure, in whole or in part, of fractures within the subsurface formation106, including the first dominant fracture212. FIG.2Bis a second graph250illustrating additional data corresponding to the fracturing operation illustrated by graph200ofFIG.2Aand, more specifically, additional data corresponding to the occurrence of microseismic events within the active well120during the fracturing operation ofFIG.2A. The data illustrated in the second graph250generally corresponds to experimental results observed during fracturing operations similar to that depicted inFIG.2A. Microseismic events are represented in the second graph250as circular indicators, such as indicator260, with the relative magnitude of the microseismic event indicated by the relative size of each indicator. As illustrated in the second graph250, initial fracturing of the active well120occurs between time interval t1to t3and results in microseismic events displaced progressively farther into the subsurface formation from the active wellbore. When the flow of fracturing fluid is reduced at time t3, microseismic events occur nearer the active wellbore, as indicated by a first cluster262. The microseismic events are generally the result one or more of closure of fractures formed during the prior high flow rate cycle and the formation of new fractures and/or propagation of existing fractures closer to the active wellbore. As described in more detail below, a second rate cycling occurs at time interval t7. The second rate cycling results in a second cluster264of microseismic events near the wellbore. Similar to the first cluster262, the second cluster264generally corresponds to closure of fractures formed in the previous high flow rate period (i.e., time interval t4to t5), or formation of new fractures or propagation of existing fractures near the wellbore. The closure of fractures or slowing of growth during a rate cycle aids in the treatment of smaller, non-dominant fractures by diverting the fracturing fluid away from the dominant fracture. More specifically, the energy required to reinitiate the slowed or closed fracture may exceed that required to begin propagating one of the other smaller, non-dominant fractures. The opening of fractures near the wellbore results in higher fracture intensity and/or complexity near the wellbore and, as a result, greater production from the well. At time t4, a second fracturing cycle is initiated by increasing the fracturing fluid flow rate to that used during time interval t2to t3. Similar to time interval t2to t3, the increased flow rate of fluid into the active well120induces a pressure increase within the monitor well122, as indicated by a third slope226which is less negative than the baseline slope220. Notably, the third slope226is also more negative than the second slope224observed during time interval t2to t3(i.e., during formation and propagation of the first dominant fracture212). Based on the difference between the second slope224and the third slope226and the fact that the fracturing fluid flow rate is substantially identical during the two time intervals, it can be inferred that the first dominant fracture212receives a lesser proportion of the fracturing fluid being pumped into the active well120. In other words, a higher proportion of the fracturing fluid is being diverted to secondary fractures, promoting propagation of the secondary fractures. As noted above, allowing fractures within the subsurface formation to partially or completely close promotes fracturing fluid flow into secondary fractures nearer the wellbore. In certain implementations, the increased diversion of fracturing fluid to secondary fractures observed during time interval t4to t5is achieved without the use of known chemical or mechanical diversion techniques, thereby resulting in improved efficiency of the well completion process. In chemical diversion, for example, a first fluid is pumped into the wellbore that solidifies and seals certain fractures in order to divert fracturing fluid to other, unsealed fractures or portions of the wellbore. Following fracturing, a second fluid is pumped into the well to dissolve the first fluid. Similarly, in mechanical diversion, a mechanical device, such as a ball or packer assemblies, is used to temporarily plug a first portion of the wellbore to divert fracturing fluid to a second portion of the wellbore. Subsequently, the mechanical device must be either dissolved or drilled out to reestablish fluid communication with the first portion of the wellbore. Each of these traditional diversion methods requires additional fluid pumping cycles and/or tool runs, resulting in increased completion time and costs. As the secondary fractures propagate, one of the secondary fractures may overtake the first dominant fracture212. As shown in illustration206F and indicated by time interval t5to t6, a second dominant fracture214has propagated into the poroelastic region134and overtaken the first dominant fracture212. Overtaking by one of the secondary fractures may be observed as a variation in the rate of pressure change within the monitor well122. In the graph200, the fourth slope228corresponds to a rate of pressure change when the first dominant fracture212is dominant. Accordingly, if a rate of pressure change is observed within the monitor well122that differs from the fourth slope228, it can be inferred that a secondary fracture has overtaken the first dominant fracture212. In the graph200, the rate of pressure change within the monitor well changes at time t5to a fifth slope230, indicating a change in the growth rate of the dominate fracture, potentially being the emergence of a new dominant fracture, i.e., the second dominant fracture214. Unlike the pressure increase experienced during time interval t2to t3, the pressure increase induced during time interval t5to t6is insufficient to cause an increase in pressure within the monitor well122but merely causes a further decrease in the leak off rate. At time t6, a second rate cycle is initiated by reducing the fracturing flow rate for a second time. This reduction induces another relaxation of the poroelastic region134, facilitating a return of the monitor well122to the baseline leak off rate observed during time interval t0to t1. At time t7, a third fracturing cycle is initiated by increasing the fracturing fluid flow rate. The process of cycling fracturing fluid flow rate can be repeated as many times as required to achieve sufficient fracturing of the subsurface formation106. Whether sufficient fracturing of the subsurface formation106has been achieved may be determined using various techniques including, without limitation, counting the occurrence of a predetermined number of rate cycles, pumping a predetermined volume of the fracturing fluid into the active well, pumping the fracturing fluid for a predetermined time, observing temperature changes within the subsurface formation, and observing microseismic events within the subsurface formation. In certain implementations, completion of the fracturing operation may be determined by pressure responses in the monitor well. For example, the fracturing operation may be deemed completed when subsequent rate cycling does not induce variable pressure responses in the monitor well122or any pressure response at all. Such behavior of the monitor well122may indicate that either fracturing fluid is no longer being diverted to fractures other than the dominant fracture or that the majority of fractures from the active well already overlap the transducer fracture. FIG.3is a flow chart illustrating an example method300for controlling rate cycling during a fracturing operation. With reference to the well completion environment100(shown inFIG.1), example method300includes an operation302that determines a baseline rate of pressure change in the monitor well122. Determining the baseline rate of pressure change may include observing pressure within the monitor well122over time, such as by referring to pressure measurements obtained from a pressure gauge144coupled to a monitor wellhead126over a known time interval. In certain implementations, the baseline rate of pressure change corresponds to a leak off rate of the monitor well122. Prior to obtaining a baseline pressure rate change, the monitor well122may be pressurized. In certain implementations, pressurization of the monitor well122occurs as a result of completion of the monitor well122. For example, the monitor well122is pressurized as a result of a fracturing operation applied to the monitor well122. In other implementations, the monitor well122may be pressurized by injection of fluid, such as water, into the monitor well122. In one specific example, the monitor well may be filled with water and the leak off rate measured thereafter. The volume of fluid (water) in the well provides hydrostatic pressure sufficient to measure leak off rate, in one example. After obtaining a baseline rate of pressure change and coupling, an operation304changes the flow rate of fracturing fluid into a well to be fractured, such as the active well120shown inFIG.1. More particularly, after the baseline rate of pressure change is obtained, the flow rate of fracturing fluid into the active well120is increased. In one implementation, a pumping system132injects the fracturing fluid into the active well120. Stated differently, fracturing may be initiated in the active well while at the same time monitoring pressure, or some other parameter sufficient to infer a poroelastic effect between the monitor and the active well, at the monitor well. As fracturing fluid is pumped into the active well120, an operation305couples the active well120to the monitor well122. In certain implementations, the coupling operation includes poroelastically coupling the active well120to the monitor well122. In alternative implementations, the active well120and the monitor well122are directly coupled and in fluid communication instead of or in addition to being poroelastically coupled. Subsequent operations306,308identify or otherwise determine the rate of pressure change in the monitor well122and whether the difference between the rate of pressure change in the monitor well122and the baseline rate of pressure change obtained during operation302exceeds a first predetermined threshold. As long as the difference does not exceed the first predetermined threshold, operations306and308are repeated, either continuously or at discrete time intervals. In other words, the rate of pressure change within the monitor well122is observed and compared to the baseline rate of pressure change to determine when injecting fracturing fluid into the active well120creates a pressure response in the monitor well122. The pressure response observed in the monitor well122is due, at least in part, to the poroelastic coupling between the active well120and the monitor well122and the transmission of pressure from the active well120to the monitor well122through the poroelastic region134. The present disclosure contemplates any number of possible fracturing fluid pumping parameter changes based on the pressure response in the monitor well. The difference in slope may be used, the time at which some difference is maintained, the degree of change in pressure, as well as other factors. Hence, various possible parameters and combination of parameters may be used as a threshold. Similarly, the number and type of response to the change may be any number of possibilities. For example, one rate cycle may occur, stepped cycles may occur, cycles may occur at different intervals and to different degrees, other changes, such as proppant or viscosity changes may be coordinated with the changes. When the observed difference between the dynamically measured rate of pressure change and the base line rate of pressure change exceeds the predetermined threshold, an operation310changes the flow rate of fracturing fluid into the active well120. In certain implementations, the flow rate is decreased to a lower flow rate, including no flow, for a predetermined period of time. In such implementations, the previously injected fluid may be permitted to flow from the active well into a tank or other storage system. In still other embodiments, the flow rate may be increased. In addition to changing the flow rate of fracturing fluid into the active well120, an operation311to modify characteristics of the fracturing fluid may be carried out. For example, and without limitation, one or more of the density, viscosity, proppant type, proppant concentration, additive concentration, and other characteristics of the fracturing fluid may be modified in response to the rate of pressure change observed in the monitor well. In certain implementations, an operator may manually change the flow rate of fracturing fluid provided by the pumping system132in response to a system generated prompt. For example, the computing system150may generate commands or prompts, in response to some change in the monitor well pressure, guiding the operator to adjust the flow rate provided by the pumping system132. Commands may be sent directly to the pumping system132or may generate an alert, prompt, or similar response on a control panel, graphical user interface, or other device of a user of the pumping system132. In alternative embodiments, the pumping system132is communicatively coupled to a computing device, such as the computing system150ofFIG.1, that is configured to receive pressure measurements from the monitor well122and to provide control signals to the pumping system132. In certain implementations, the fracturing fluid flow rate is reduced during operation310. After reduction of the fracturing fluid flow rate, operations312,314determine the rate of pressure change in the monitor well122and whether the difference between the rate of pressure change in the monitor well122and the baseline rate of pressure change obtained during operation302are below a second predetermined threshold. As long as the difference is above the second predetermined threshold, operations306and308are repeated, either continuously or at discrete time intervals. In other words, the rate of pressure change within the monitor well122is observed and compared to the baseline rate of pressure change to determine when the pressure response observed in the monitor well122has subsided, thereby indicating sufficient relaxation of the poroelastic region134between the active well120and the monitor well122. After such subsidence, the fluid flow rate of the fracturing fluid and the fracturing fluid characteristics are again modified in operations315and316, respectively, thereby initiating a second rate cycle. Subsequent cycles may be conducted until sufficient fracturing of the active well120is achieved. In alternative implementations, the duration for which a flow rate is maintained before rate cycling can be based on observations of microseismic events within the active well120. As previously discussed in the context ofFIGS.2A and2B, reducing the flow rate of the fracturing fluid pumped into the active well120generally leads to the occurrence of microseismic events near the wellbore, which generally indicate closure of fractures or formation and/or propagation of fractures other than the dominant fracture. Accordingly, observation of such microseismic events may be used to determine when to increase the flow rate of fracturing fluid. For example, in certain implementations the flow rate of the fracturing fluid is increased when one or more microseismic events occurs having a minimum predetermined magnitude and/or within a predetermined distance from the wellbore. Alternatively, a flow rate may be maintained for some period of time and/or at some prescribed level prior to rate cycling. Hence, a second threshold is not used to determine when to change flow rates. Method300is intended only as an example embodiment of a method in accordance with the present disclosure and alternative implementations are possible. In one alternative implementation, flow rate of the fracturing fluid is increased and/or decreased in response to the difference between the baseline rate of pressure change and the observed rate of pressure change being maintained for a predetermined amount of time. In still other implementations, other parameters may be modified in addition to or instead of the flow rate of the fracturing fluid. Such parameters include, without limitation, the type of fracturing fluid being used, the relative proportion of components of the fracturing fluid, the amount or type of proppant added to the fracturing fluid, and the amount or type of other additive either added to or excluded from the fracturing fluid. Moreover, modifications to any parameters associated with the fracturing operation may vary from rate cycle-to-rate cycle. For example, the flow rates used during one rate cycle may differ from prior or subsequent rate cycles. In certain implementations, properties of the fracturing fluid including, without limitation, one or more of the density, viscosity, proppant type, proppant concentration, additive concentration, and other characteristics of the fracturing fluid may be modified in response to the rate of pressure change observed in the monitor well122. For example, rate cycling may induce only a minor variation or no variation in the rate of pressure change within the monitor well122. Such minimal changes may indicate that a less than desirable amount of the fracturing fluid is being diverted away from the dominant fracture. To promote diversion of fracturing fluid, various techniques may be applied. For example, the size and/or concentration of proppant may be increased to promote bridging in the dominant fracture, thereby obstructing the flow of fracturing fluid into the dominant fractures. In another technique, the viscosity of the fracturing fluid may be changed. More specifically, a high viscosity fracturing fluid may be used to form a high viscosity “plug” in the dominant fracture that prevents or resists a subsequently injected low viscosity fluid from entering the dominant fracture. The example implementation of the present disclosure illustrated inFIG.1included a monitor wellhead126and corresponding pressure gauge144for measuring pressure within the monitor well122. In the example, the monitor well122defines a single volume such that pressure changes induced by poroelastic coupling between the active well120and any portion of the monitor well122are reflected by pressure gauge144. In other implementations, however, a monitor well may be divided into isolated intervals with each interval having a respective pressure gauge (or similar sensor adapted to measure pressure) and a respective transducer fracture. By doing so, pressure responses in each interval may be monitored to detect fracture propagation through distinct portions of a subsurface formation. The pressure responses may then be used to modifying fracturing operation parameters, thereby controlling fracturing operations. FIG.4is a table400illustrating a portion of an example fracturing operation plan and, more specifically, a fracturing operation plan that includes automated rate cycling and subsequent monitoring of the success of the automated rate cycling. As shown, the table400includes entries for each of stages47and48of the fracturing operation. In general, the fracturing operation plan includes instructions and operational parameters for conducting one or more fracturing operations, each of which may include multiple stages. For example, the instructions may include, among other things, activating, deactivating, or modifying the performance of one or more pieces of equipment for carrying out the fracturing operation and/or changes to parameters governing operation of such equipment. The fracturing operation may further include thresholds, limits, and other logical tests. Such tests may be used, for example, to generate alerts or alarms, to initiate control or other routines, to select subsequent operational steps, or to modify current or subsequent steps in the fracturing operation. In implementations of the present disclosure, the fracturing operation plan may be executed, at least in part, by a computing system and the fracturing operation plan may be stored within memory accessible by the computing system. For example, in certain implementations the fracturing operation plan may include computer-executable instructions that may be executed by the computing system in order to control at least a portion of a fracturing operation. Executing the fracturing operation plan may then cause the computing system to, among other things, issue commands to equipment in accordance with the fracturing operation plan, receive and analyze data related to steps in the fracturing operation plan, and update or otherwise modify parameters of the fracturing operation plan in accordance with the received data. The fracturing operation plan may also include instructions for operations that require manual intervention by an operator. For example, in some implementations, executing a fracturing operation in accordance with the fracturing operation plan may require an operator to provide confirmation or acknowledgement prior to a computing system executing one or more steps of the fracturing operation plan. In other implementations, more direct intervention by the operator may be required. For example, the operator may be required to manually activate, deactivate, or modify performance parameters of equipment. Referring now to the example fracturing operation illustrated by the table400, an initial trigger402is provided for each stage of the fracturing operation. The trigger402is generally a condition that, when met, initiates a rate cycle operation, as indicated in the “Action” column404. For example, in stage47, the trigger to initiate rate cycling is an increase of 5 psi within the monitor well following initiation of the first ramp. The first ramp generally corresponds to the first injection of fracturing fluid and initiation of fracture propagation for the stage. Similarly, in stage47, the rate cycling trigger is an increase of 20 psi following the first ramp. Notably, the trigger of either of stages47and48may be dynamically determined, at least in part, by pressure responses observed in the monitor well during fracturing of one or prior stages. In response to the trigger, rate cycling is initiated by reducing the fracturing fluid injection rate for a predetermined amount of time. For stages47and48, such rate cycling includes reducing the injection rate of fracturing fluid to 0 bpm for three minutes. Following a rate cycle, each stage may also include a test to determine the effect of the rate cycling. As noted in table400, the test406for each of stages47and48is an observed rate of pressure change decrease of more than 20%. If such a decrease in the rate of pressure change is observed, the fracturing operation proceeds according to the base schedule per column408. If, however, no such pressure rate decrease is observed within a predetermined time (e.g., five minutes), a subsequent rate cycle may be initiated or other adjustments to the fracturing operation parameters may be applied, as shown in column410. For example, as indicated for each of stages47and48, the fracturing fluid is changed to a linear gel fracturing fluid. FIG.5is a schematic illustration of a pumping system500for use in systems according to the present disclosure. Pumping system500includes a primary fluid storage502coupled to a pump or pumps504and505configured to pump fluid from primary fluid storage502along an outlet506and to a wellhead of an active well to facilitate fracturing of the active well. A proppant system508, an additive system510, and a blender516are further coupled to an outlet506. Each of the proppant system508, the additive system510, and the pump504are further communicatively coupled to a computing device512. In certain implementations, computing device512is also communicatively coupled, either directly or indirectly, to a display of a control panel, human machine interface, or similar computing device. During operation, the computing device512transmits control signals to the pump504to control pumping of fluid from the primary fluid storage502by the pump504. As fluid is pumped from the fluid storage502to the active well through the outlet506, proppants and other additives may be introduced into the fluid by the proppant system508and the additive system510, respectively. In the pumping system500, each of the proppant system508and the additive system510are each communicatively coupled to and controllable, at least in part, by the computing device512. Accordingly, the computing device512can control the amount of proppant and additive introduced into the fluid. The outlet506may further include a blender516or similar mixing device configured to mix the fluid from the primary fluid storage502with proppants introduced by the proppant system508and/or additives introduced by the additive system510. The pumping system500may also operate, at least in part, based on control signals received from a user. For example, the pumping system500includes a display518or similar device for providing system data, alerts, prompts, and other information to a user and for receiving input from the user. As shown inFIG.5, the display518may be used to prompt a user to confirm initiation of a change to the flow rate of fracturing fluid provided by the pumping system500. In alternative implementations, the display518may further allow the user to receive other prompts and to issue other commands, such as those corresponding to operation of the proppant system508, the additive system510, or other components of the pumping system500. In certain implementations, the primary fluid storage502is coupled to the wellhead to permit recycling of fluid during a fracturing operation. Return fluid from the wellhead may require filtering or other processing prior to reuse and, as a result, the pumping system500may further include or be coupled to equipment configured to treat return fluid. Such equipment may include, without limitation, settling tanks or ponds, separators, filtration systems, and reverse osmosis systems. As illustrated inFIG.5, the computing device512is communicatively coupled to a network514and is configured to receive data over the network514. For example, in certain implementations the computing device512receives pressure measurements taken from a monitor well, such as the monitor well122shown inFIG.1, and/or control signals from a control system or other computing device, such as computing system150(shown inFIG.1), derived from such pressure measurements. Computing device512then controls the pumps504,505, the proppant system508, the additive system510, and other components of the pump system500based on the measurement data and/or control signals. In alternative implementations, one or more components of the pump system500are manually controlled, at least in part, by an operator. For example, in certain implementations, the output of the pumps504,505is manually controlled by an operator who receives pressure measurement data from a second operator at the monitor well122or by reading a gauge or display configured to communicate pressure within the active well120. Fracturing Operation Monitoring Using Sealed Monitor Wells In the previous implementations discussed herein, fracturing operations for a target well were monitored in part using an offset/monitor well. More specifically, pressure changes within the monitor well resulting from poroelastic coupling between a monitoring fracture (or factures) of the monitor well and the fractures formed during fracturing of the target well are used to determine progress of the fractures of the target well and, subsequently, to control fracturing operations (e.g., by triggering a rate cycle). In another aspect of the present disclosure, systems and methods are provided for monitoring of hydraulic fracturing treatments using a sealed monitor well instead of the monitoring fracture of the previous implementations. The sealed monitor well may be cased but unperforated and substantially filled with a fluid (e.g., water). In certain applications, sufficient fluid may be present in the monitor well due to previous well operations. However, in other applications, additional fluid may be added to the sealed monitor well prior to sealing the monitor well to completely fill the monitor well to surface with fluid. The monitor well is fitted with one or more pressure transducers, which may be disposed at various locations within the monitor well and/or installed in a wellhead of the monitor well. As fractures from an adjacent target well approach and/or overtake the monitor well, force is exerted on the monitor well, increasing the internal pressure of the monitor well as measured by the pressure transducers. Based on measurements of such pressure changes, the progress of fracturing operations of the target well may be ascertained. Like the previous implementations discussed herein, fracturing operations of the target well may then be controlled or otherwise modified in response to the pressure changes observed in the monitor well. Various sections of the monitor well could also be isolated from each other and pressure may be monitored in each section. By doing so the monitor well may be divided into distinct chambers or monitoring portions to better define the subsurface effects being monitored. Sectioning of the monitor well may be achieved, for example, by bridge plugs, packers, or other suitable isolation tools. In certain implementations transducers may be deployed via a tubing string to monitor pressure in each isolated section. Monitor wells for use in the systems and methods described herein may be preexisting wells or may be drilled specifically for purposes of monitoring fracturing operations. In general, however, the monitor wells are preferably located proximate the target well such that the monitor well extends across a growth path for fractures extending from the target well and, if possible, transverse or generally perpendicular to the predominant fracture growth direction. In some instances, the monitor well, or at least a portion thereof, will be generally parallel the well bore being fractured. During fracturing operations of the target well, hydraulic fractures approach the monitor well and induce stresses in the rock surrounding the monitor well. As such stresses increase, such as by the introduction of additional hydraulic fracturing fluid into the target well, portions of the monitor well may be compressed. Such compression may result in pressure changes (increases) within the monitor well for several reasons. For example, assuming that the monitor well is substantially sealed, the pressure change within the monitor well may be a result of the compressive forces from the fracture and associated fracturing fluids intercepting or otherwise interacting with the monitor well casing and thereby acting upon fluid contained within the monitor well. Pressure increases may also be observed due to compression of the monitor well casing reducing the inner diameter of the monitor well, thereby causing the level of liquid maintained within the monitor well to increase and, as a result, the hydraulic head provided by the liquid. In certain cases, interaction between the hydraulic fractures extending from the target well and the monitor well may also be observed as an initial reduction in pressure within the sealed monitor well. For example, as a fracture extends from the target well, the forces and pressures within the formation associated with the propagating fracture may reduce in-situ stresses on the monitor well and, as a result, may cause a decrease in pressure within the monitor well. Once the fracture reaches the sealed monitor well, the net stress (added to the steady state in-situ stresses) induced by the extending fracture may switch from being tensile to compressive. In the immediate vicinity of the fracture surface, the induced compressive stresses may be approximately equal to the fracture fluid pressure within the extending fracture at the point of interest. Accordingly, a pressure reduction may be observed as the fracture approaches the monitor well followed by an increase in pressure once the fracture tip passes the monitor well. In certain implementations, a single monitor well may be used to monitor fracturing operations for two or more target wells. In one example, a single monitor well may be used to facilitate a “zipper” fracturing operation for multiple target wells. Such an operation may generally include fracturing of multiple target wells in an alternating manner to improve overall operational efficiency. For example, a first stage of a first well may be plugged and perforated using a wireline or similar tool. As the first stage of the first well is fractured, a first stage of a second well may be plugged and perforated, preferably (although not necessarily) from the same or a nearby well pad such that the same wireline tool and pumping system may be used in the second well. A second stage of the first well may then be plugged and perforated while the first stage of the second well is fractured. This process is repeated for each stage of the first and second wells. In such implementations, a monitor well may be disposed between each of the multiple wells undergoing fracturing operations to direct or control such operations. For example, a single monitor well may be disposed between the first well and the second well to determine when a given stage of the first well has been sufficiently fractured and, as a result, when to begin fracturing a corresponding stage of the second well (and vice versa). In another example operation, the monitor well may be positioned between a depleted region and two or more target wells being completed in a zipper operation. Alternatively, the monitor well may be located on the opposite side of the depleted area such that the depleted area and the two or more target wells are disposed on the same side of the monitor well. The target wells may then be alternatingly completed using the monitor well to determine whether completion order is affecting fracture propagation direction. For example, if stages in a target well further away from the region of depletion are fractured ahead of comparable stages of a target well closer to the region of depletion, the fractures in the target well closer to the region of depletion could be driven towards the depleted region. By monitoring pressure within the monitor well, one may identify such interactions between the target wells and may determine fracture order or delays between zipper operations to minimize such interactions. One or more pressure transducers may be disposed along the monitor well or otherwise positioned to measure pressure within the monitor well. Without limitation, example locations for pressure transducers include at a heel of the monitor well, at a toe of the monitor well, at one or more intermediate locations between the heel and the toe, and at the wellhead of the monitor well. In certain implementations, pressure transducers may be disposed along the monitor well that correspond to different stages of the target well. By providing pressure transducers at multiple locations along the monitor well, additional information regarding the actual or approximate location at which fractures from the target well overtake the monitor well may be ascertained. In certain implementations, the information from the pressure transducers may also be supplemented or validated by strain measurements obtained from strain gauges or one or more optical fibers disposed along the wellbore and which measure strain on the casing caused by interactions with the fracture of the target well. For example, and without limitation, such strain measurement devices may be distributed along the casing of the monitor well, particularly between the heel and the toe of the monitor well and could include discrete strain gauges of optical fibers. Pressure gauges or similar pressure and/or force measurement devices may also be used to monitor external formation pressure and forces exerted by the formation on the monitor well, providing additional details regarding fractures extending from the target well and the monitor well. In certain implementations, communication may be established between the formation and such external gauges by perforation shots directed away from the monitor well into the rock using a perforation gun located on the casing exterior of the monitor well. In another implementation, the inner diameter of the monitor well casing may be divided into discrete, isolated chambers, each having its own pressure transducer. Internal pressure sensing transducers could also be deployed inside the casing via tubing with isolation between sections via packers or deployed on the casing outer diameter and ported to the inner diameter. In general, pressure measurement devices configured to measure pressure of a common, open portion of a wellbore will exhibit substantially the same pressure response as each other. Accordingly, to the extent pressure within specific portions of the monitor well are to be observed, such portions may be isolated (e.g., using packers, etc.) to define separate pressure measurement zones or monitoring portions/sections. However, it should be appreciated that maintaining fluid communication between at least a portion of the wellbore and a wellhead may be advantageous. For example, a pressure transducer disposed at a relatively shallow location within the well can be used to detect pressure responses caused by interactions of fractures and the monitor well provided the location of measurement by the pressure transducer is in fluid communication with the location of the interaction (e.g., by disposing the pressure transducer below a water or similar fluid level in the well bore). Advantages of doing so include, but are not limited to, a reduction in the required transducer pressure rating and improved pressure measurement resolution. Although strain measurements are described herein as being used to validate or as otherwise supplemental to pressure measurements, systems and methods described herein may also rely on strain measurements as the primary (e.g., with pressure measurements used as supplemental data) or the only way of identifying interactions between the monitor and target wells. Accordingly, to the extent the foregoing disclosure discusses the use of pressure transducers and pressure measurements, it should be appreciated that strain gauges and strain measurements may generally be implemented in a similar manner. As previously discussed, the pressure response measured in the monitor well may be, at least in part, due to pressure exerted on a fluid sealed within the monitor well. To the extent air or other compressible fluid is disposed within the sealed monitor well (for example, near the wellhead), such compressible fluid may negatively impact the accuracy, resolution, and timeliness with which pressure responses within the monitor well may be detected. Accordingly, the monitor well may be prepared such that the monitor well is substantially filled with a liquid, such as water. For example, water may be pumped or otherwise provided into the monitor well prior to fracturing of the target well and air or other compressible fluids may be substantially removed from the monitor well prior to sealing the monitor well. FIG.6is a schematic diagram of an example well completion environment600for completing a fracturing operation in accordance with the present disclosure. The well completion environment600includes a subsurface formation606through which an active or target well620and a monitor well622extend. The target well620includes a vertical active well section602and a horizontal active well section604. Similarly, the monitor well622is also a horizontal well and includes a vertical monitor well section608and a horizontal monitor well section610. The monitor well622and target well620are shown from substantially offset vertical sections; however, it is also possible that the monitor well622and the target well620may be initiated from the same pad. Thus, the relative orientation of the wells620,622is provided as an example and should not be construed as limiting. In implementations of the present disclosure, the monitor well622may generally be located relative to the target well620such that the monitor well622is likely to interact with fractures extending from the target well620. For example, the monitor well622may be located to at least partially extend through the same strata of the subsurface formation through which the target well620passes and/or may be disposed at a particular distance from the target well620to which it may reasonably be assumed that fractures will extend. In contrast to the monitor well122of the well completion environment100discussed in the context ofFIG.1, the monitor well622may be sealed. For example, as illustrated inFIG.6, each of the vertical monitor well section608and the horizontal monitor well section610may be encompassed by a casing611. The horizontal well section610may also include a plug613or similar downhole feature such that the internal volume of the monitor well622is closed. In alternative implementations of the present disclosure, one or both of the target well620and the monitor well622may be vertical wells. In some instances, a monitor well may be one that will be completed, or has been completed, and may in some instances be a producing well or previously producing well. Moreover, implementations of the present disclosure may include more than one active well and/or more than one monitor well. Accordingly, one or more monitor wells may be used to monitor fracturing of one or more active wells. The target well620includes a target wellhead624disposed at a surface630. Similarly, the monitor well622includes a monitor wellhead626at the surface630. The monitor wellhead626may further include multiple pressure gauges and transducers for measuring pressure at various locations within the monitor well622. For example, the monitor well622includes each of a wellhead pressure transducer644, a heel pressure transducer646located in or near the heel of the monitor well622, a toe pressure transducer648located near the toe of the monitor well622, and an intermediate pressure transducer650disposed between the heel pressure transducer646and the toe pressure transducer648. The pressure transducers646,648, and650are positioned to measure pressure within monitor well622. It should be appreciated that the quantity and placement of pressure transducers in implementations of the present disclosure are not limited to the arrangement illustrated inFIG.6and any suitable number of pressure transducers for measuring pressure within the monitor well622may be used. In addition to pressure transducers644,646,648, and650, various other sensors and transducers may be used in implementations of the present disclosure. For example, each of the heel pressure transducer646, the intermediate pressure transducer650, and the toe pressure transducer648are supplemented with a respective strain gauge, strain transducer, or other externally sensing pressure transducers652,654, and656. Each of the strain gauges652,654, and656is coupled to the casing611adjacent the respective pressure transducer646,648, and650. Accordingly, each of the strain gauges652,654, and656may measure strain on the casing611at their respective locations. It should be appreciated that while the strain gauges652,654, and656are shown as having a one-to-one relationship with the pressure transducers646,648, and650, more or fewer strain gauges may be used in other implementations of the present disclosure and the strain gauges may be positioned at locations along the casing611that do not necessarily correspond to a location of a pressure transducer. Moreover, different combinations of sensors are possible, and implementations without pressure sensors are possible. Fiber based sensing arrangements that can detect a fracture approaching and/or intercepting the monitor well are also possible. For example, a fiber optic-based strain gauge may be disposed on the casing611to facilitate strain measurements. Each of the pressure transducers644,646,648, and650may be configured to measure pressure within a respective monitoring portion of the monitor well622. To do so, one or more packets, plugs, or similar isolation tools may be disposed at various locations within the monitor well622. For example, as illustrated inFIG.6, three packers670,672, and674, are disposed at various locations within the monitor well622to form three distinct sections of the monitor well622, each including a respective one of the pressure transducers644,646,648, and650to measure pressure within the section. Another example of sensors that may be used in implementations of the present disclosure include, without limitation, externally sensing pressure transducers. In one example implementation, such transducers may be installed with perforation guns on the outer diameter of the casing611and perforations may be shot away from the casing611(i.e., not penetrating the casing). As a result, the perforations together with the externally sensing pressure transducers form a pressure sensing system that will sense fractures extending from the target well620as they approach the monitor well622. Yet another type of sensor that may be used in implementations of the present disclosure is a contact stress or tactile pressure sensor, which generally measure contact stresses or contact pressure between two mating surfaces. Accordingly, such sensors may be mounted to an exterior surface of the casing611to measure contact forces and pressure exerted onto the outer surface of the casing611. Each of the gauges, sensors, and transducers of the well completion environment600is adapted to obtain a corresponding measurement. Such measurement data may then be transmitted to a computing system680. In the well completion environment600, the computing system680is communicatively coupled to a pumping system632(illustrated inFIG.6as including a pump truck635) such that the computing system680can transmit pressure data, control signals, and other data to the pumping system632to dynamically adjust parameters of the fracturing operation based on pressure measurements received from the monitor well622and monitor well wellhead626. The pumping system632generally provides fracturing fluid into the target well620and, in certain implementations, may include additional equipment for modifying characteristics of the fracturing fluid and/or the manner in which the fracturing fluid is injected into the target well620. Such equipment may be used, for example, to add or change a proppant or other additive of the fracturing fluid in order to modify, among other things, the viscosity, proppant concentration, proppant size, or other aspects of the fracturing fluid. Accordingly, such equipment may include, without limitation, one or more of tanks, pumps, filters, and associated control systems. The computing system680may include one or more local or remote computing devices configured to receive and analyze the pressure data to facilitate control of the fracturing operation. The computing system680may be a single computing device communicatively coupled to components of the well completion environment600, or forming a part of the well completion environment600, or may include multiple, separate computing devices networked or otherwise coupled together. In the latter case, the computing system680may be distributed such that some computing devices are located locally at the well site while others are maintained remotely. In certain implementations, for example, the computing system680is located locally at the well site in a control room, server module, or similar structure. In other implementations, the computing system is a remote server that is located off-site and that may be further configured to control fracturing operations for multiple well sites. In still other implementations, the computing system680, in whole or in part, is integrated into other components of the well completion environment600. For example, the computing system680may be integrated into one or more of the pumping system632, the target wellhead624, and the monitor wellhead626. The pressure transducers644,646,648,650(and any other transducers or sensors, such as the strain gauges652,654,656) are communicatively coupled to the computing system680, such as by respective transmitters. Similar transducers and sensors may also be installed or disposed in the target well620and communicatively coupled to the computing system680to measure or otherwise obtain data regarding conditions in the target well620. Although described herein as measuring pressure and strain, other transducers and sensors that may be implemented in the well completion environment600may also measure temperature, flow rate, level, various chemical measurements, or any other condition or quantity that may be of interest in either the target well620or the monitor well622. Well completion environment600is depicted after perforation but before fracturing of the target well620. Accordingly, active well horizontal section604includes a plurality of perforations638that extend into the formation606from the target well620. In the implementation illustrated inFIG.6, the perforations638are formed and extend from an uncased portion of the target well620into the surrounding formation606. In contrast, in implementations in which fracturing operations are to occur in a cased portion of a target well, the perforations would also extend through the well casing. The perforations638may be formed during the initial completion of the target well620to direct fracturing fluid into the subsurface formation606at the respective perforations. For example, in certain completion methods, casing is installed within the well and a perforating gun is positioned within the target well620adjacent the portion of the subsurface formation606to be fractured. The perforating gun includes shaped charges that, when detonated, create perforations that extend through the casing and into the adjacent formation, thereby creating an initial fluid path from the target well620into the formation. During fracturing, fracturing fluid is pumped into the target well620and the fluid passes through the perforations638under high pressure and rate. The injection of fracturing fluid into the formation at the perforations forms one or more fractures that emanate from the well into the subsurface formation606. The fractures form fluid paths between the subsurface formation606and the target well620so that oil and/or gas in the formation flows to and into the well. Alternative fracturing methods may also be used in conjunction with the systems and methods disclosed herein. For example, in certain implementations, the fracturing operation is an open-hole fracturing operation. In contrast to methods in which a casing is installed and then perforated prior to fracturing, open-hole fracturing is performed on an unlined section of the wellbore. Generally, open-hole fracturing involves isolating sections of the uncased wellbore using packers or similar sealing elements. Sliding sleeves or similar valve mechanisms disposed between the packers are then opened to permit pumping of the fracturing fluid into the surrounding formation. As pressure within the formation increases, fractures are formed and propagated. In multi-stage wells, this process is repeated for each stage moving up the wellbore. Of course, multi-stage fracking may also be performed in a cased well. The active wellhead624is coupled to a pump system632for pumping fracturing fluid into the target well620. In the well completion environment600, for example, the pump system632includes a pump truck635coupled to the active wellhead624. The pump truck635includes a tank or other means for storing the fracturing fluid and a pump connected to the active wellhead624for pumping fluid into the target well620. In other embodiments, the pump system632includes other equipment for providing fracturing fluid to the target well620including, without limitation, storage tanks or other vessels and one or more additional pumps. The pump system632may further include equipment configured to modify the fracturing fluid, for example, by adding one or more additives, such as proppants or chemicals, to the fracturing fluid. The pump system632may also include equipment, such as filters, to treat and recycle fracturing fluid. As shown in the implementation ofFIG.6, the pump system632, and more particularly pump truck635, is communicatively coupled to the computing system680. Accordingly, the pump truck635can receive sensor data, control signals, or other data from the computing system680, including data configured to be used in controlling and monitoring of an ongoing fracturing operation. In addition to being sealed, the monitor well622may contain and be substantially filled with a liquid, such as water. In certain implementations, during preparation of the monitor well622, liquid may be introduced into the monitor well622or otherwise allowed to substantially fill the monitor well622in order to displace air, gaseous hydrocarbons, or other highly compressible fluids or media that may be present in the monitor well622. By doing so, the monitor well622may be made to be more responsive to applied stresses than if the monitor well622contained the highly compressible fluid. For purposes of this disclosure, the term “substantially filled” should not be interpreted to mean any specific degree to which the monitor well622is filled. Rather, the monitor well622is sufficiently filled if the amount of fluid present within the monitor well622provides improvement in detecting a pressure response of the monitor well622due to interactions with a fracture extending from the target well620as compared to if the monitor well622did not contain any such fluid. FIGS.15A-Dare cross-sectional views of the well completion environment600illustrating the formation and propagation of fractures from the target well620toward the monitor well622to illustrate various aspects of the present disclosure. In the following description, reference is also made to elements of the well completion environment600illustrated inFIG.6. Referring first toFIG.7A, each of the target well620and the monitor well622are shown prior to injection of fracturing fluid. For simplicity, only one perforation638is illustrated extending from the target well620, however, it should be appreciated that multiple perforations may extend from the target well620in multiple directions. As pumping system632pumps fracturing fluid into the target well620, the fracturing fluid enters the subsurface formation606through the perforations638. As the fracturing fluid continues to enter the subsurface formation606, pressure within a portion of the subsurface formation606adjacent the perforations638increases, leading to the formation and propagation of fractures639within the subsurface formation606, as illustrated inFIG.7B. As illustrated inFIG.7C, as the fractures639grow and continue to propagate outward toward the monitor well622, stresses are induced in the portion of the subsurface formation606disposed between the target well620and the monitor well622. Such stresses may result in force being applied to the monitor well622and may result in deformation of the monitor well622or, more specifically the casing611of the monitor well. Such deformation results in change of pressure within the monitor well622which may be attributable to the external pressure exerted on the casing611and/or the change in hydraulic head caused by the changing diameter of the casing611. The change of pressure within the monitor well622may generally be an increase as the fracture crosses the path of the monitor well622, however, in at least some cases the pressure within the monitor well622may also decrease as the fracture approaches the monitor well622and relieves in-situ stresses within the formation606. Accordingly, while the current disclosure focuses on pressure increases as being the primary change indicating interaction between fractures of the target well620and the monitor well622, implementations of the present disclosure may also rely on pressure decreases within the monitor well622as indicative of interactions between the fracture and the monitor well622. Although illustrated inFIG.7Cas resulting in a lateral compression of the monitor well622, it should be appreciated that such deformation is not intended to be to scale and illustrates just one possibility of deformation that may result from stresses induced in the subsurface formation606. Actual deformation of the monitor well622may differ and may depend on, among other things, the actual direction of propagation of the fracture639from the target well620, the relative location and change of location relative to the monitor well622(above, below, intercepting, etc.) and the various properties of the subsurface formation606. As the fractures continue to propagate and cross the path of monitor well622, as illustrated inFIG.7D, the compressive effects on the monitor well622may increase, resulting in further deformation of the monitor well casing611and increased pressure within the casing611. Pressure changes within the monitor well622provide information regarding the propagation of fractures from the target well620and, as a result, identifying and characterizing such pressure changes may be used to control fracturing operations, among other things. Generally, pressure changes observed in the monitor well622during pumping of fracturing fluid into the target well620indicate when fractures extending from the target well620have propagated near or have crossed the path of the monitor well622. Accordingly, the time between initiating injection of fracturing fluid into the target well620and a corresponding response in the monitor well622, the total fluid volume pumped into the active stage before identifying a response in the monitor well622, the degree of the pressure response in the monitor well622, the rate of change of the pressure within the monitor well622, and other information related to the pressure response (or other sensed response) in the monitor well622may be used to control one or more fracturing operation parameters or otherwise inform fracturing operations. Fracturing operation parameters generally refers to any aspect of a fracturing operation that may be controlled or varied to modify the fracturing operation. Example fracturing operation parameters include, without limitation, fracturing fluid viscosity, proppant size, proppant concentration, fracturing fluid additive ratios, fracturing fluid injection rate, fracturing fluid injection duration (e.g., for rate cycling), duration between pumping cycles, fracturing fluid injection pressure, fracturing fluid composition, and the like. As previously discussed, pressure transducers may be disposed at various locations of the monitor well622, such as the heel pressure transducer646, the intermediate pressure transducer650, and the toe pressure transducer648. By implementing multiple pressure transducers along the length of the monitor well622, localized pressure changes may be observed and, as a result, the approximate location of fractures inducing such pressure changes may be inferred. As illustrated inFIG.6, identifying the location of the fractures may be facilitated by isolating portions of the wellbore (such as by using packers670-674) and using one or more pressure transducers to measure pressure within each isolated portion of the monitor well622. Accordingly, when a pressure response is measured by a particular subset of the pressure transducers, it may be assumed that fractures have crossed the monitor well622at some point along the corresponding section. Another advantage gained by isolating sections of the monitor well622and including pressure transducers for measuring pressure responses in each isolated section is that the pressure response in the smaller section increases and is therefore more easily observable than if the monitor well was not subdivided. For example, in a 20,000 foot well (as measured from surface to toe) without isolation and filled with a fluid, the entire fluid volume is compressed as a fracture approaches and/or crosses over the monitor well622. As a result of the compressibility of the fluid within the well, the observed response in an “open” (i.e., without isolation) 20,000 foot well may be relatively small (e.g., on the order of only 1 psi). However, if a bridge plug or similar device is set at 10,000 feet (or any other depth that divides the wellbore), the sensed pressure change in the lateral would double (e.g. on the order of 2 psi) because only half of the fluid is available to be compressed as is available in the fully open scenario. Further subdividing the monitor well622further increases the response. Continuing the current example, suppose a 10,000 foot lateral portion of the well is divided into five 2,000 foot sections, each of which is isolated from each other. If a fracture were to cross the monitor well622near the center of one of the 2,000 foot sections, the induced pressure change would be on the order of 10 psi since only 1/10th of the entire fluid volume of the monitor well622is being compressed. Accordingly, in addition to being useful in determining the approximately location at which a fracture has approached/crossed the monitor well622, isolating and monitoring sections of the monitor well622improves the sensitivity with which the monitor well622is able to detect such interactions. In an example application, suppose a dominant fracture propagates from the target well620to overtake the monitor well622near the toe of the monitor well622. If the toe portion of the monitor well622is isolated, only the toe pressure transducer648may register a pressure increase, may register a pressure increase before the other pressure transducers (for example, if the dominant fracture expands to cross two sections of the monitor well622), or may register a pressure increase that is greater than the other pressure transducers. As a result, it may be assumed that the dominant fracture is likely in the vicinity of the toe of the monitor well622. The location of dominant fractures may also be inferred from other sensors, such as the strain gauges652-656. For example, if a dominant fracture extends from the target well620and overtakes the monitor well622near the toe of the monitor well622, the toe strain gauge654may measure strain on the monitor well casing611that precedes and/or exceeds strain measured by the strain gauges652,656disposed at the heel and intermediate locations of the monitor well622. Moreover, other strain sensors may not detect a change from a fracture proximate a distant sensor. As previously noted, if sections of the monitor well622are not isolated, each pressure transducer along the monitor well622may register approximately the same pressure measurement at steady state. However, by observing how pressure changes propagate through the monitor well622, an approximation of the location at which a fracture crosses the monitor well may be ascertained. In other words, while pressure may ultimately equalize along the length of the monitor well622, different portions of the monitor well622may reach pressure at slightly different times. As a result, the earliest locations to reach pressure may be used to approximate the location of the fracture. Other measurements, such as strain, may also be used alone or in combination with pressure measurements in open wells to facilitate identification of fracture locations. Notably, while the target well620shown inFIG.6is illustrated as including only a single stage, systems and methods in accordance with the present disclosure may be applied to multi-stage wells. More specifically, the target well620may be divided into multiple stages that are consecutively plugged, perforated, and fractured and the monitor well622may be used to monitor the formation and propagation of fractures for each stage. In certain implementations, the monitor well622may include multiple groups of one or more pressure transducers or similar sensors distributed along the wellbore with each of the groups aligning or otherwise corresponding with a respective stage of the target well620. Accordingly, as each stage of the target well620is fractured, respective responses may be observed in the monitor well622Nonetheless, in some implementations a limited set of sensors or simply one sensor may be used to measure responses of the monitor well. The pressure response of the monitor well622may vary in applications in which multiple fractures from the target well620cross the monitor well622. For example, an initial fracture may cross the monitor well622, resulting in a first increase in pressure within the monitor well622. When propagation of this initial fracture halts and pressure within the initial fracture begins to subside (e.g., due to fluid leak off from the fracture being greater than fluid being supplied to the fracture), a corresponding decline in pressure within the monitor well622may be observed. If a second fracture from the target well620(or other well) subsequently crosses the monitor well622(e.g., following a rate cycle or similar operation), a second, smaller pressure increase as compared to that observed with the initial fracture may be observed in the monitor well622. If a third fracture subsequently crosses the monitor well622, the pressure response of the monitor well622may be dependent on the location at which the third fracture crosses the monitor well622. For example, if the third fracture is between the first and second fractures, little to no response may be observed in the monitor well622. However, if the third fracture is not disposed between the first and second fractures, another pressure increase may be observed in the monitor well622. Following a fracturing operation and, in particular, after cessation of pumping fracturing fluid into any fractures formed during such an operation, the fracturing fluid may gradually leak into the surrounding formation, which may be observed in the monitor well622as a gradual decline in pressure. When pressure within the monitor well622returns to pre-fracturing operation levels, it may be assumed that the fractures induced during the operation have closed (which may, in certain cases, require hours or days to occur). Accordingly, pressure changes within the monitor well622following a fracturing operation may be used to determine when closure time has occurred and when to initiate subsequent well operations. FIG.8is a graph800illustrating an example fracturing operation consistent with the foregoing description. The graph800illustrates various metrics over time during an example fracturing operation. More specifically, the graph800includes a first line802indicating fracturing fluid injection rate into the target well620, a second line804indicating first pressure measurements taken at a first location of the monitor well622, and a third line806indicating second pressure measurements taken at a second location of the monitor well622. For purposes of the current example, the first location of the monitor well622(indicated by the second line804) is assumed to be a toe of the monitor well622and, as a result, the pressure measurement indicated by the second line804may correspond to measurements obtained from the toe pressure transducer648. Similarly, the second location of the monitor well622indicated by the third line806is assumed to be at an intermediate location of the monitor well622and, as a result, the pressure measurement indicated by the third line806may correspond to pressure measurements obtained from the intermediate pressure transducer650. For purposes ofFIG.8, it is assumed that the pressure lines804,806correspond to pressure measurements obtained from pressure transducers disposed in respective isolated sections of the wellbore. Referring still toFIG.8, beginning at t1, the fracturing fluid injection rate is gradually increased to a first injection rate at time t2. During the time period between t1and t2, the pressure in each of the first location and the second location of the monitor well622remains substantially constant, indicating that fractures have not yet sufficiently propagated from the target well620to interact with the monitor well622. At time t3, a pressure change is observed in each of the first and second monitor well locations, indicating that a dominant fracture from the target well620has sufficiently propagated toward and influenced pressure within the monitor well622. As illustrated by the difference in slope between the toe pressure measurement line804and the intermediate pressure measurement line806, the dominant fracture has likely propagated at or near the toe of the monitor well622and, more specifically, has approached and/or crossed the isolated section of the monitor well622corresponding to the toe. As previously mentioned, the location of the dominant fracture may be verified by, among other things, strain gauge readings corresponding to locations of the casing611of the monitor well622. At time t4, a rate cycle is initiated by reducing the fracturing fluid injection rate from the first rate and eventually stopping injection at time t5(at time t5it is also possible that the rate may be substantially reduced from the first rate (e.g., 90 barrels per minute to 10 barrels per minute)). In response, the pressures and stresses within the formation may gradually subside, as indicated by a gradual decline in the pressures observed in the monitor well and indicated by lines804and806. As previously discussed, rate cycling by alternating periods of high fracturing fluid injection with low or no fracturing fluid injection may enable the development and propagation of other additional fractures extending from the target well620and, as a result, to promote more complete fracturing of the subsurface formation606. AlthoughFIG.7illustrates an immediate decline in monitor well pressure in response to reducing the fracturing fluid injection rate, it should be appreciated that in certain cases a delay may be present between the reduction in injection rate and an observed pressure response in the monitor well622. Such a delay may depend on, among other things, the leak off rate into the surrounding formation. Also, pressure within the monitor well622may continue to increase after reducing injection rate and even if pressure within the target well620decreases as fluid may continue to flow towards the tip of the fracture. At time t6, the injection rate is increased until a target injection rate is reached at time t7. At time t7and until time t8, there is not a pressure response in the monitor well, which may indicate that the fracture that caused the first pressure increase is not growing but rather that new fractures are propagating from the target well620. At time t8, the pressure within the monitor well622is again observed as increasing, indicating that stresses induced by the injection of fracturing fluid into the target well620are causing corresponding pressure responses in the monitor well622. However, unlike during the time period of t3to t4, in which a greater response was observed in the toe of the monitor well622, the time period beginning at t8indicates a sharper response in the intermediate portion of the monitor well622and, as a result, indicates the development of fractures proximate the intermediate portion of the monitor well622. In other words,FIG.8indicates that the rate cycling undertaken was successful in forming and/or propagating additional fractures from the target well620. As previously noted,FIG.8illustrates a case in which pressure lines804and806are obtained from pressure transducers disposed in respective isolated sections of a monitor well. In other implementations, however, the pressure transducers may be disposed at different locations of an open (i.e., not isolated) well or disposed in the same isolated portion of the monitor well622. In such cases, the pressure measurements obtained from such transducers may be substantially the same (e.g., a slight offset may be present due to differences in hydrostatic head attributable to the location of the transducers within the monitor well622) or otherwise track each other throughout the fracturing operation. Accordingly, to differentiate when new fractures cross the monitor well622other metrics may be required. For example and without limitation, in one implementation the location of a fracture may be approximated by determining which pressure transducer leads the other (provided the pressure transducers sample the pressure within the monitor well622at a sufficiently high rate). In other implementations, other sensors may be used alone or in combination with the pressure transducers to determine the location of fractures. For example, strain gauges or other force sensors disposed on the casing of the monitor well622may be used to determine the location of forces applied to the casing by propagating fractures. FIG.9is a schematic illustration of an alternative well environment900including a first target well902, a second target well904, and a monitor well906, which may be sealed, extending through a subsurface formation901and illustrates the use of the single monitor well906for monitoring and controlling fracturing operations in each of the target wells902,904. As illustrated, the monitor well906is generally disposed between the target wells902,904such that the monitor well906may intercept fractures propagating from each of the target wells902,904. The monitor well906and each of the target wells902,904are shown from substantially offset vertical sections; however, it is also possible that the monitor well906and target wells902,904may be initiated from the same pad. Thus, the relative orientation of the wells is provided as example and should not be construed as limiting. Moreover, it should be appreciated that the location of the monitor well906ofFIG.9is provided as an example and, as a result, should not be viewed as limiting. For example, in the specific context ofFIG.9, any of wells902,904, and906may be configured as a monitor well for operations conducted on the other two wells. More generally, in multi-well applications, the monitor well906is positioned such that it may intercept fractures extending from any number of target wells. Each of the target wells902,904is divided into a respective set of stages. More particularly, the first target well902is divided into stages903A-D (from the toe to the heel of the first target well902) and the second target well904is divided into stages905A-D (from the toe to the heel of the second target well904). During completion, each stage of each of the target wells902,904may be fractured in order from the toe to the heel, the heel to the toe, or any other suitable order. Fracturing generally includes a process of isolating the stage being fractured (such as by installing a downhole isolation plug), perforating the stage, and pumping fracturing fluid into the perforations to form and propagate fractures from the active target well into the surrounding formation. As illustrated inFIG.9, each of the target wells902,904includes a respective wellhead assembly908,910adapted to be coupled to a pumping system912. The pumping system912may generally include equipment adapted to control injection of fracturing fluid into the target wells902,904and general processing of such fracturing fluid. Among other things, the pumping system912may be adapted to modify the injection rate and/or pressure of the fracturing fluid, size, and/or concentration of proppant in the fracturing fluid, concentration of any additives in the fracturing fluid, and any other similar parameter associated with injecting fracturing fluid into either of the target wells902,904. Although illustrated as being coupled to a shared pumping system912, each of the target wells902,904may instead by coupled to a respective pumping system, each of which is adapted to monitor and control fracturing operations for one of the target wells902,904. The monitor well906and the target wells902,904are shown from substantially offset vertical sections; however, it is also possible that the wells902-906may be initiated from the same pad. Thus, the relative orientation of the wells is provided as example and should not be construed as limiting. The monitor well906may also include a wellhead914, may be at least partially sealed, and may be at least partially filled with a liquid, such as water, or other relatively incompressible substance to facilitate observations of pressure responses within the monitor well906. In one implementation, the monitor well906may be encompassed by a casing918and may include one or more plugs (not shown) to seal portions of the monitor well906. The monitor well906may further include various sensors disposed in the wellhead914, along the casing918, or within the casing918to monitor pressure within the monitor well906, strain on the casing918, and other operational parameters. For example, the monitor well906includes multiple pressure transducers920A-D disposed along its length as well as corresponding strain gauges922A-D coupled to the casing918. As illustrated inFIG.9, each of the pressure transducers920A-D is disposed in a respective isolated section of the monitor well906. In particular bridge plugs970A-D are installed along the length of the monitor well906to form the isolated sections of the monitor well906. Nevertheless and as previously discussed in the context ofFIG.6-8, in at least some implementations of the present disclosure, the monitor well906may be at least partially open such that the pressure transducers920A-D measure pressure within the same volume. Although discussed herein as being cased but not completed, it should be appreciated that monitor wells in accordance with the present disclosure may also be at least partially completed. For example, in one implementation a partially completed (e.g., a well including at least one fracture) well may be configured as a monitor well by installing a solid bridge plug or similar isolation tool above the uppermost fracture. By doing so, a sealed portion of the well is isolated from any previously completed portions. Internal pressure of the sealed portion may then be monitored and used to assess interaction of the well with the offset wells being completed. Each of the pumping system912and the various sensors and transducers of the monitor well906are communicatively coupled to a computing system950. The computing system950is generally configured to receive measurements from the sensors of the monitor well906and, based on the received measurements, to control operation of the pumping system912. As described below in more detail, the monitor well906is used to monitor and facilitate fracturing operations for each of the target wells902,904. In one example implementation, the monitor well906may be used to facilitate alternate fracturing of stages of the first target well902with those of the second target well904. For example, the monitor well906may be used to monitoring fracturing operations for the toe stage903A of the first target well902. In response to determining that sufficient fracturing of the toe stage903A has occurred (e.g., by a suitable pressure response of the monitor well906), the computing system950may then initiate fracturing of the toe stage905A of the second target well904. This process may be repeated for at least some of the remaining stages of the target wells902,904 As illustrated inFIG.9, the target wells902,904extend through the subsurface formation901in substantially opposite directions and originate from separate well pads. However, in other implementations, the target wells902,904may extend adjacent to one another and/or may originate from a common well pad. For example, in so-called “zipper” fracturing operations, multiple target wells are drilled such that at least a portion of the wells are substantially parallel to one other. Such target wells may also extend from a common well pad. The stages of the target wells are then fractured alternately. For example, a first stage of a first target well is fractured followed by a first stage of a second target well followed by a second stage of the first target well, and so on. It should be appreciated that alternately fracturing the wells may include fracturing one or more stages at a time. In other words, a first set of stages may be fractured in the first well followed by a first set of stages of the second well, followed by a second set of stages of the first well, and so on, with each set of stages including one or more stages. In addition to providing a more complete fracturing of the subsurface formation through which the target wells extend, such operations may provide substantial efficiencies by allowing each well to be serviced/completed from a single well pad and/or by enabling preparation (e.g., plugging and perforating) of stages of one of the target wells during fracturing of the other. In applications in which multiple wells may be fractured from a common well pad, the wellheads of such wells may include a manifold adapted to redirect flow of fracturing fluid between the target wells. In such cases, the manifold (or other similar valve systems for redirecting fracturing fluid flow between target wells) may also be in communication with the pumping system912and/or the computing system950such that the pumping system912and/or the computing system950may control the flow of fracturing fluid between the target wells. FIG.10is a graph1000illustrating an example fracturing operation consistent with the foregoing description of fracturing multiple target wells using a single monitor well. The graph1000illustrates various metrics over time during an example fracturing operation. More specifically, the graph1000includes a first line1002indicating fracturing fluid injection rate into the first target well902, a second line1004indicating fracturing fluid injection rate into the second target well904, a third line1006indicating first pressure measurements taken at a first location of the monitor well906, and a fourth line1008indicating second pressure measurements taken at a second location of the monitor well906. For purposes of the current example, the first location of the pressure transducer in the monitor well906(indicated by the third line1006) is assumed to be at a heel of the monitor well906(or more specifically an isolated heel section of the monitor well906) and, as a result, the pressure measurements indicated by the third line1006may correspond to pressure measurements obtained from the heel pressure transducer920D. Similarly, the second location of the pressure transducer in the monitor well906(indicated by the fourth line1008) is assumed to be at a toe of the monitor well906(or, more specifically, an isolated toes section of the monitor well906) and, as a result, the pressure measurement indicated by the fourth line1008may correspond to measurements obtained from the toe pressure transducer920A. Beginning at t1, the fracturing fluid injection rate for the first target well902is gradually increased to a first injection rate at time t2. During the time period between t1and t2, the pressure in each of the first location and the second location of the monitor well906remains substantially constant, indicating that fractures have not yet sufficiently propagated from the first target well902to interact with the monitor well906. At time t3, a pressure change is observed at the first monitor well location (i.e., the isolated heel portion of the monitor well906), indicating that a dominant fracture from the first target well902has sufficiently propagated toward and influenced pressure within the monitor well906, as measured by pressure transducer920D. The presence of the dominant fracture from the first target well902may be verified by, among other things, strain gauge readings obtained from the strain gauge922D. In contrast, the pressure measurements obtained at the toe pressure transducer920A location (i.e., the isolated toe portion of the monitor well906) remain relatively unchanged. At time t4, the fracturing fluid injection rate for the first target well902is reduced from the first rate. In the specific illustrated example, this decrease eventually results in complete cessation of fracturing fluid being provided into the first target well902at time t5. Alternatively, the fracturing fluid injection rate may instead be reduced to a sufficiently low level that interactions between the first target well902and the monitor well906are significantly reduced. In either case, reducing the fracturing fluid injection rate may cause the pressures and stresses within the formation to gradually drop, as indicated by a gradual decline in the pressures observed in the heel of the monitor well906between times t4and t6. At time t6, fracturing of the second target well904begins. More specifically, the fracturing fluid injection rate for the second target well904is increased until a target injection rate is reached at time t7. At time t8, the pressure within the monitor well906is again observed as increasing. However, such increase is observed primarily in the isolated toe portion of the monitor well906, indicating that dominant fractures from the toe stage905A of the second target well904have sufficiently propagated to influence pressure within at least a portion of the monitor well906. When such a response is detected, the injection of fracturing fluid into the second target well904may be reduced or stopped, as indicated by the transition between times t9and t10. The foregoing process may be repeated for additional stages of the target wells902,904. In other words, fracturing fluid may be injected into a stage of the first target well902until a sufficient pressure or other response is detected in the monitor well906. After such a response, fracturing fluid may be diverted or otherwise provided to the second target well904to fracture a corresponding stage of the second target well904. As previously discussed, during periods in which one of the target well902,904is being fractured, the other target well may be prepared for a subsequent fracturing operation, such as by running wireline or similar tools to plug and/or perforate the target well not currently being fractured. In certain cases, preparation for subsequent fracturing operations may include pumping fluid downhole. For example, plug and perforating tools are often transported downhole using a pump down operation. Such pumping activities in a previously fractured well may result in a response in the monitor well due to at least some of the fractures remaining open. Accordingly, in certain multi-well implementations of the present disclosure, differentiation must be made between monitor well responses attributable to preparation-related activities and those attributable to propagation of fractures from wells being actively fractured. In some cases, such differentiation may be achieved by identifying where the pressure response is observed. For example, if previously formed fractures from a first well crossed a toe portion of the monitor well and a second well is being actively fractured in proximity to the heel of the monitor well, pressure responses observed in the toe portion of the monitor well during both preparation activities in the first well and active fracturing of the second well may be disregarded (or otherwise not attributed to the active fracturing of the second well). While the pressure transducers in the foregoing example are described as being in isolated sections of the monitor well, it should be appreciated that in other implementations, the pressure transducers may be disposed at different locations of an open (i.e., not isolated) well or disposed in the same isolated portion of the monitor well. In such cases, the pressure measurements obtained from such transducers may be substantially the same or otherwise track each other. Accordingly, to differentiate when new fractures cross the monitor well and, in particular, when fractures originate from a first well of a multi-well operation versus a second well, other metrics may be required. For example and without limitation, in one implementation the location of a fracture may be approximated by determining which pressure transducer leads the other. In other implementations, other sensors may be used alone or in combination with the pressure transducers to determine the location of fractures. For example, strain gauges or other force sensors disposed on the casing of the monitor well may be used to determine the location of forces applied to the casing by propagating fractures. In either case, the location of fractures crossing the monitor well in combination with known information regarding the location of the wells being fractured and likely fracture propagation paths for each well, may be used to identify when fractures from a given well have crossed the monitor well. FIG.11is a flow chart illustrating an example method1100of fracturing one or more target wells in a subsurface formation. In general, such fracturing is facilitated by a monitor well that extends through the subsurface formation. More specifically, the monitor well is positioned relative to the target well(s) such that as fractures propagate through the subsurface formation and induce stresses therein, a corresponding pressure response is observable within the monitor well. Based on such pressure responses, parameters of the fracturing operation may be dynamically modified. At operation1102the monitor well is prepared. Preparation of the monitor well may include one or more of drilling the monitor wellbore, installing a casing within the monitor well and sealing a portion of the monitor wellbore. To improve the pressure response of the monitor well, the monitor well may also be filled with a liquid, such as water. Accordingly, preparation of the monitor well may further include injecting liquid into the monitor well. Injecting liquid into the monitor well may also facilitate the removal of gases and other relatively compressible fluids from within the monitor well that may negatively impact the responsiveness of the monitor well. Preparation of the monitor well may also include installation of subsurface transducers in the monitor well and/or splitting the monitor well into two or more separate pressure chambers, each with its own transducer, to monitor individual, isolated pressure responses at specific locations along the monitor well. In implementations in which preparation of the monitor wellbore includes actual drilling to the monitor wellbore, such drilling may be performed to locate the monitor well such that the monitor well extends through a plane perpendicular to at least a portion of the intended target well. For example, the monitor wellbore may be drilled to be at least partially parallel to the target well. In implementations in which multiple target wells are to be fractured, the monitor well may be drilled to extend between the target wells or it may be located such that all target wells are on one side of the monitor well. In general, however, the monitor well may be drilled such that the monitor well extends through a location in the subsurface formation through which fractures of the target well are likely to propagate or within which stresses are likely to be induced during fracturing of the target well. With the monitor well prepared, a fracturing fluid is pumped into the target well according to one or more fracturing operation parameters (operation1104). As fracturing fluid is pumped into the target well resulting in formation and/or propagation of fractures from the target well and, more specifically, from perforations formed in the target well. As the fractures propagate through the subsurface formation, they extend toward the monitor well and induce a measured pressure response within the monitor well (operation1106). To measure the pressure response, the monitor well includes one or more pressure transducers or similar sensors configured to measure pressure within the monitor well and to communicate such measurements to a computing system. One or more pressure transducers may be distributed along the monitor well and/or may be located within a wellhead of the monitor well. In general, the measured pressure response may correspond to any change in pressure within at least a portion of the monitor well. For example and without limitation, the measured pressure response may be an absolute change in pressure, a relative change in pressure, an increase or decrease in a rate of pressure change, or any other pressure-related metric. In certain implementations, one or more additional sensors may be used to verify and locate the pressure response. For example, and without limitation, one or more strain gauges may be disposed along the casing of the monitor well to measure deformation of the casing in response to stresses induced in the subsurface formation during fracturing operations. Like the measured pressure response, the measured strain response may be considered to indicate a fracture if a measured strain response meets certain criteria. For example, and without limitation, the measured strain response may correspond to an absolute change in strain, a relative change in strain, an increase or decrease in a rate of change of strain, or any other strain-related metric. As illustrated inFIG.11, the process of injecting fracturing fluid (operation1104) and measuring the pressure response within the monitor well (operation1106) may be repeated until, for example, a particular response (e.g., a pressure increase, a pressure decrease, a rate of pressure change, etc.) is measured. In response to identifying and optionally verifying the pressure change response within the monitor well, one or more of the fracturing operation parameters may be modified (operation1108). In one example implementation, modifying the fracturing operation parameters may include reducing the fracturing fluid injection rate, including reducing the injection rate to zero. Modifying the fracturing operation parameters may also include, without limitation, one or more of modifying the injection rate and/or pressure of the fracturing fluid, modifying the size and/or concentration of proppant in the fracturing fluid, changing a concentration of any additives in the fracturing fluid, and changing any other similar parameter associated with injecting fracturing fluid into the target wells. In one example implementation, modifying the fracturing operation parameters may include each of reducing an injection rate for a first target well and increasing an injection rate for a second target well. In implementations in which each of the first target well and the second target well are coupled to respective pumping systems, each pumping system may be controlled to change the injection rates. In other implementations in which fracturing fluid is provided to both target wells from a common pumping system, modifying the injection rates for the target wells may include actuating one or more valves or similar fluid control devices to adjust the proportion of fracturing fluid delivered to each target well. Additional aspects of fracturing operations and monitoring of fracturing operations according to the present disclosure are provided in U.S. patent application Ser. Nos. 16/362,214 and 15/879,187, each of which is incorporated herein by reference in their entirety and for all purposes. As noted above, an operator may use sealed monitor wells or sealed portions of a monitor well to identify propagation of fractures from other wells within the same formation due to interactions between the fractures and the monitor well. For example, as a fracture propagates through the formation, resulting forces may be transferred from the propagating fracture, through the formation (e.g., due to poroelastic coupling of the monitor well and fracture or other modes of energy transfer between the fracture and monitor well) and to the monitor well casing. Such forces may cause deformation of the monitor well casing, reducing the internal volume of the monitor well wellbore. To the extent the monitor well is sealed or flow from the monitor well is otherwise restricted, such changes to the internal volume of the monitor well may result in an observable pressure increase within the monitor well, among other indications. However, the pressure response in the monitor well may be subtle and, as a result, detection of the response may be subject to other forces and phenomena. For example, temperature changes within the monitor well may cause fluid within the monitor well to expand, thereby increasing pressure within the monitor well. Such temperatures changes may be the result of fluid disposed within the monitor well (including fluid added to the monitor well) being heated by the surrounding subsurface formation. Generally speaking, aspects of the present invention involve monitoring fluid flow from a well, which fluid flow may be due in part from pressure changes due to conditions within the well such as temperature, and differentiating between the conditions induced fluid flow and fracture driven fluid flow to isolate and otherwise detect fracture interactions within a well. More particularly, to account for thermally induced pressure changes within the monitor well, the present disclosure includes a fracture monitoring system that relies on fluid flow to identify interactions between the monitor well and fractures of a target well. The fracture monitoring system generally includes a flow meter and corresponding controller for measuring flow from a pressure control valve configured to control pressure within the monitor well. More specifically, when pressure increases within the well, the pressure control valve opens, a portion of fluid from within the monitor well exits through the pressure control valve, and the flow meter measures one or more attributes of the flow from the monitor well. Based on the attribute, the controller determines whether the flow is the result of thermally induced flow or other factors, such as interaction with a fracture from a target well. In certain implementations, such determinations are made by obtaining a baseline value or measurement for an attribute of flow measured by the flow meter before initiating a fracturing operation. The controller then compares the baseline to subsequently obtained values or measurements for the attribute. To the extent the controller determines the later obtained value/measurement is inconsistent with the baseline value/measurement or otherwise meets a similar criteria, the controller may transmit an indicator, such as a message or command signal, indicating interaction between the monitor well and the fracture has occurred. When received by a well monitoring system, the indicator may generate an alert for personnel to address, initiate or otherwise be involved with modifying fracturing operations, or perform other similar functions. FIG.12is an illustration of a well environment1200including a monitor well1202in a subsurface formation1252. Monitor well1202includes a wellbore1206including a casing1204extending through subsurface formation1252and an optional downhole packer/plug1209. Monitor well1202further includes a wellhead1208that caps wellbore1206and through which fluids may be extracted or introduced into wellbore1206. As discussed herein, monitor well1202may be used to detect fracture propagation from a target well in subsurface formation1252. More specifically, as fractures propagate from the target well during a fracturing operation, forces are transferred from the fractures, through subsurface formation1252, and to casing1204. The transferred forces squeeze casing1204, simultaneously decreasing the volume of wellbore1206and increasing pressure within wellbore1206. Accordingly, by monitoring for certain changes in monitor well1202, monitor well1202can be used to analyze propagation of fractures from the target well and to control fracturing operations accordingly. In certain implementations, the response of monitor well1202can be improved by substantially sealing wellbore1206of monitor well1202(or a monitoring portion of monitor well1202) and filling wellbore1206with a fluid1250, such as, but not limited to water or fracturing fluid, and which may be in a substantially liquid state. Among other things, substantially sealing wellbore1206controls for various external factors and provides a baseline wellbore condition against which changes resulting from interactions with a target well fracture can be readily identified. Filling wellbore1206with a liquid (e.g., water), on the other hand, generally improves the responsiveness of monitor well1202to such interactions. In contrast, when wellbore1206includes an air gap or similar gas at its head, the relative compressibility of the gas compared to a liquid may make changes in wellbore1206harder to identify versus when wellbore1206is substantially filled with a liquid. Nevertheless, in certain implementations, an air gap may be present within wellbore1206. In such implementations, flow meter1214may be adapted to measure one or both of gas and liquid flow from wellbore1206. Although sealing monitor well1202and filling monitor well1202with a liquid are beneficial, thermal changes in fluid1250can obfuscate the presence and/or cause of pressure changes in monitor well1202. Typically, fluid1250is injected into wellbore1206at a temperature that is below, and sometimes substantially below, a temperature of subsurface formation1252. Accordingly, after injection, fluid1250is heated by subsurface formation1252. Such heating causes an expansion of fluid1250(or gaseous components of fluid1250) and, if monitor well1202is sealed, a corresponding pressure increase within wellbore1206. Such thermally induced pressure changes to monitor well1202may obfuscate pressure changes due to interactions with fractures extending from the target well. Stated differently, in certain cases, fracture-induced changes in monitor well1202may be incorrectly attributed to thermal expansion of fluid1250, while in other cases, thermally induced changes in monitor well1202may be incorrectly identified as fracture-induced changes. The problem of distinguishing between thermally induced and fracture-induced pressure changes in monitor well1202may be particularly pronounced shortly after initial injection of fluid into wellbore1206. In most contexts, the temperature difference between fluid1250and subsurface formation1252would be relatively high at that time. As a result, substantial heat transfer from subsurface formation1252to fluid1250may occur, contributing to substantial pressure changes within wellbore1206. If a fracturing operation were to be conducted while fluid1250is undergoing substantial expansion, contributions of fractures from the target well to pressure within wellbore1206may be difficult to distinguish from pressure changes caused by thermal expansion of fluid1250based on pressure measurements alone. Accordingly, if an operator were to rely exclusively on pressure measurements to monitor fracture propagation, the operator may attribute fracture-induced pressure changes to thermal expansion or vice versa. To address the foregoing issues, among others, monitor well1202includes a fracture monitoring system1210that controls pressure within wellbore1206and identifies interactions between monitor well1202and fractures from target wells based on flow. As illustrated, fracture monitoring system1210generally includes a device body1212that may be coupled to an outlet of wellhead1208and that may define a flow path1213between wellhead1208and an outlet of fracture monitoring system1210. Fracture monitoring system1210further includes each of a flow meter1214, a pressure control valve1216, and a pressure sensor1218in communication with flow path1213. In certain implementations, a controller1220or similar computing device may be communicatively coupled to one or more components of fracture monitoring system1210to receive signals/data and/or control the one or more components. For example, controller1220is shown inFIG.12as being communicatively coupled to each of flow meter1214and pressure sensor1218to receive flow measurements from flow meter1214and pressure measurements from pressure sensor1218. Controller1220may also be configured to communicate with a well control/monitoring system or similar centralized computing system. Notably, while illustrates as being a separate component attached to wellhead1208, in other implementations, fracture monitoring system1210may be coupled to wellhead1208by being integrated with wellhead1208. When in use, pressure control valve1216is configured to maintain wellbore1206at a predetermined pressure by permitting flow from wellbore1206when wellbore1206exceeds the predetermined pressure. To do so, pressure control valve1216is set at the predetermined pressure. While wellbore1206, or whatever wellbore feature connected to the valve and in fluid communication with the wellbore, is below the set pressure of pressure control valve1216, pressure control valve1216remains closed and wellbore1206remains sealed. When pressure within wellbore1206exceeds the set pressure of pressure control valve1216, pressure control valve1216opens, permitting flow of fluid1250through device body1212. When pressure within wellbore1206subsequently drops, pressure control valve1216closes, resealing wellbore1206. Flow meter1214is in-line with and downstream of pressure control valve1216and is configured to measure attributes of liquid passing through pressure control valve1216when pressure control valve1216is in an open state. Measurements obtained from flow meter1214may be transmitted to and processed by controller1220, which, in turn, may be configured to discriminate between thermally induced flow changes and flow changes from interactions between monitor well1202and a fracture extending from a target well. Pressure sensor1218may be included in certain implementations and may generally be used to verify pressure within wellbore1206, as controlled by pressure control valve1216. As illustrated, pressure sensor1218is also in communication with controller1220and may be configured to transmit signals to controller1220that correspond to pressure measurements obtained by pressure sensor1218. In at least certain implementations, installation, and configuration of fracture monitoring system1210may include removing gas from wellbore1206, e.g., eliminating an air gap at a top of pressure control valve1216. To do so, additional liquid may be injected into wellbore1206, wellbore1206may be vented through wellhead1208, etc. Alternatively, fluid1250may be permitted to undergo an initial expansion, e.g., from formation heating, prior to closing pressure control valve1216, thereby pushing out any gas that may otherwise form an air gap within wellbore1206. FIG.13is a graph1300illustrating various parameters of monitor well1202preceding a fracturing operation of a target well in subsurface formation1252. Graph1300is described with reference to well environment1200ofFIG.12with specific reference to monitor well1202, fracture monitoring system1210, and their respective elements. Graph1300includes a temperature line1302indicating temperature of fluid1250within monitor well1202. Graph1300further includes a pressure line1304indicating pressure within monitor well1202. As described below, pressure line1304is further illustrated as splitting into uncontrolled pressure line1306and controlled pressure line1308. Graph1300is intended to illustrate general operating principles of fracture monitoring system1210in the context of monitor well1202. Accordingly, graph1300and the example data represented in graph1300are intended for explanatory purposes only and should not limit the present disclosure. In general, the horizontal axis of graph1300indicates time while the vertical axis indicates a suitable value for the parameters represented by the various lines of graph1300. Time t0of graph1300indicates a time after injection of fluid1250into monitor well1202. Typically, liquid injected into monitor well1202will be at a temperature substantially below the temperature of subsurface formation1252. Accordingly, as time progresses, fluid1250will increase in temperature until it becomes substantially isothermal with subsurface formation1252. This temperature change is generally indicated by the gradual increase in temperature line1302over time until ultimately plateauing at a final temperature. While monitor well1202remains sealed, the increase in temperature of fluid1250results in a corresponding increase in pressure within monitor well1202, as illustrated by pressure line1304. Absent venting or pressure relief, pressure within monitor well1202, like temperature within monitor well1202, may eventually settle as fluid1250becomes isothermal with subsurface formation1252. This trend is illustrated by uncontrolled pressure line1306, which increases with temperature line1302and eventually reaches a steady state as fluid1250similarly reaches its plateau. When fracture monitoring system1210is implemented, pressure within monitor well1202is controlled such that pressure within monitor well1202is maintained at approximately a set point of pressure control valve1216. More specifically, pressure control valve1216is configured to open in response to pressure within monitor well1202reaching/exceeding a cracking or opening pressure of pressure control valve1216(indicated by cracking pressure line1310). When opened pressure control valve1216permits flow to exit monitor well1202through device body1212of fracture monitoring system1210along flow path1213. As fluid exits monitor well1202and provided the volume of fluid exiting monitor well1202exceeds volumetric expansion of fluid1250within monitor well1202, pressure within monitor well1202reduces. When pressure within monitor well1202drops to or below a reseal pressure (indicated by reseal pressure line1312), pressure control valve1216closes, allowing pressure to rebuild within monitor well1202until it again exceeds the cracking pressure of pressure control valve1216. In the example illustrated, the pressure begins to decrease after the valve is opened; however, it should be recognized that the change in pressure and rate of change in pressure will depend on various factors including whether temperature of the fluid is continuing to rise in which case the pressure may be steady for some time or decrease at a lesser rate than when the temperature of the fluid has equalized with the formation temperature. As shown by controlled pressure line1308, the general operating cycle of pressure control valve1216may be repeated as fluid temperature within monitor well1202increases due to heating of fluid1250by subsurface formation1252. Stated differently, as temperature of fluid1250increases and fluid1250expands, pressure control valve1216occasionally opens to permit fluid flow from monitor well1202. As a result, pressure control valve1216prevents pressure within monitor well1202from exceeding the cracking pressure of pressure control valve1216for any substantial period of time. Graph1300includes a series of insets further illustrating operation of fracture monitoring system1210. Inset1314illustrates monitor well1202and fracture monitoring system1210at a time t1in which flow is not permitted through fracture monitoring system1210. More specifically, at time t1, pressure within monitor well1202is substantially below the cracking pressure of pressure control valve1216. As a result, pressure control valve1216remains sealed, thereby sealing monitor well1202, preventing flow through fracture monitoring system1210(as indicated by flow rate Q0), and permitting pressure within monitor well1202to continue to rise with temperature. In contrast, inset1316illustrates monitor well1202and fracture monitoring system1210while pressure control valve1216is open (beginning at time t2). More specifically, inset1316illustrates monitor well1202and fracture monitoring system1210after pressure within monitor well1202reaches/exceeds the cracking pressure of pressure control valve1216. As a result, pressure control valve1216opens and permits flow through fracture monitoring system1210, as indicated by flow rate Q1and flow line1320. Flow line1320may generally correspond to a flow measurement obtained by flow meter1214. As noted above, operation of pressure control valve1216may be cyclical in that pressure control valve1216may open to relieve pressure of monitor well1202as temperature increases within monitor well1202. Consistent with such operation, inset1318illustrates monitor well1202and fracture monitoring system1210during a subsequent portion of the operating cycle in which pressure control valve1216is open (beginning at time t3), thereby allowing flow through fracture monitoring system1210, as indicated by flow line1222. As illustrated by controlled pressure line1308, when flow through pressure control valve1216exceeds volumetric expansion of fluid1250within monitor well1202, pressure within monitor well1202may oscillate between the cracking and set pressures of pressure control valve1216. Alternatively, if the volume of fluid1250increases at a rate greater than the flow rate through pressure control valve1216, pressure within monitor well1202may continue to rise even through1216may be open. Nevertheless, as fluid1250becomes isothermal with subsurface formation1252, flow through pressure control valve1216will eventually exceed volumetric expansion of fluid1250within monitor well1202and pressure within monitor well1202will drop below the cracking pressure of pressure control valve1216. Notably, flow through fracture monitoring system1210during the state illustrated in inset1318may be like flow through fracture monitoring system1210during the state illustrate in inset1316. Accordingly, flow through fracture monitoring system1210in inset1318is indicated as having a flow rate of ˜Q1. More generally, flow through fracture monitoring system1210as illustrated in inset1318may have similar values for flow attributes to flow through fracture monitoring system1210as illustrated in inset1316. As a result, each of flow through fracture monitoring system1210as illustrated in inset1318and flow through fracture monitoring system1210as illustrated in inset1316may be attributed to thermal changes in monitor well1202. Even more generally, characteristics and attributes of flow through fracture monitoring system1210prior to initiation of a fracturing operation in a target well may be used to provide information useful in distinguishing thermally induced flow through fracture monitoring system1210from non-thermally induced flow though fracture monitoring system1210(e.g., due to fracture interaction). For example, measurements obtained by fracture monitoring system1210preceding a fracturing operation may be used to determine a range, a maximum, a minimum, statistical measurements (e.g., standard deviation), or any other value corresponding to thermally induced flow through fracture monitoring system1210. Such values may then be used to establish thresholds, inform models, etc., against which subsequent measurements obtained during fracturing can be tested or otherwise compared. To the extent the subsequent measurements conform to the values observed prior to fracturing, fracture monitoring system1210may determine that a fracture has not yet interacted with monitor well1202. In contrast, if the measurements deviate from the values established prior to fracturing, fracture monitoring system1210may determine that such measurement are the result of a fracturing interacting with monitor well1202. In at least certain implementations, controller1220may perform the operations of obtaining values/measurements for a flow attribute of interest and determining a baseline indicative of thermally induced flow through fracture monitoring system1210. For example, controller1220may receive measurements from flow meter1214prior to initiating a fracturing operation of the target well to establish a trend, a range, a pattern, etc. for flow absent a fracturing operation. Such data may then be used to compare subsequently obtained measurements during a fracturing operation. When controller1220determines a measurement obtained during fracturing substantial deviates from the baseline, controller1220may determine that such deviation is the result of interactions between a fracture and the monitor well and transmit a corresponding indicator. In other implementations, controller1220may be provided with or access values, ranges, thresholds, etc., indicative of fracture interactions and may compare measurements obtained during a fracturing operation with such values. FIG.14is a graph1400illustrating various parameters of monitor well1202prior to and including interaction between monitor well1202and a fracture of a target well. Graph1400is described with reference to well environment1200ofFIG.12with specific reference to monitor well1202and fracture monitoring system1210and their respective elements. Like graph1300, graph1400includes a temperature line1402and a pressure line1404indicating temperature and pressure within monitor well1202, respectively, with pressure line1404corresponding to a controlled pressure within monitor well1202, e.g., a pressure subject to control by pressure control valve1216. Graph1400further includes a flow line1406indicating flow through pressure control valve1216of fracture monitoring system1210. At time to, monitor well1202is in a substantially steady state. Nevertheless, as shown in graph1400and by temperature line1402, temperature within monitor well1202may fluctuate, and pressure control valve1216may occasionally relieve any pressure buildup within monitor well1202that results. Graph1400includes inset1416and inset1418, each of which illustrates monitor well1202and fracture monitoring system1210during relief of thermally induced pressure increases within monitor well1202(and beginning at times t1and t2, respectively). As illustrated, flow through fracture monitoring system1210is indicated as ˜Q1and may be substantially like other flow caused by thermal changes in monitor well1202, e.g., flow illustrated in inset1316and inset1318of graph1300. At time t3, a third flow occurs through fracture monitoring system1210as illustrated in inset1420. The flow beginning at time t3is notably different than the flows beginning at times t1and t2and, as a result, is labeled as Q2in inset1420. More specifically, flow at time t3has each of an increased duration, an increased flow rate, and an increased total volume as compared to the flows occurring at times t1and t2. As a result, and based on one or more of these differences, controller1220may distinguish the flow at time t3from the thermally induced flows at times t1and t2. Controller1220may further determine or identify the flow beginning at time t3as being the result of interactions between monitor well1202and a fracture extending from a target well in subsurface formation1252. In response to identifying fracture propagation, controller1220may generate a signal, message, or other indicator noting the arrival of a fracture at or near monitor well1202. In certain implementations, the indicator may be received by a well control/monitoring system. When the indicator is received, the well control/monitoring system may generate an alert, alarm, or similar response to notify personnel of the fracture status such that personnel may initiate a subsequent phase of a well completion operation. Alternatively, the indicator may cause well control/monitoring system to automatically modify a fracturing operation parameter. For example, in certain implementations, receiving an indicator corresponding to interaction between a fracture and monitor well1202may cause the well control/monitoring system to stop a fracturing operation (e.g., by stopping a pump or pumping system), to initiate a rate cycle, to modify a fracturing fluid, or to perform other similar operations automatically. The term “indicator” as used herein in the context of computing device communications refers to an instance of communication and is not intended to be limited to any specific mode or type of communication. For example, in certain cases, an indicator may be an analog or digital control signal, that, when received by another device, modifies operation of the receiving device. In such instances, generating and transmitting the indicator may include generating the control signal and sending the control signal to the receiving device, respectively. In other implementations, an indicator may correspond to a change to a table, a database, a variable, or other data accessible by other devices. In such instances, generating the indicator may include computing or otherwise determining the value for the change and transmitting the indicator may include initiating the process to update the data. In still other implementations, an indicator may correspond to a message in accordance with any suitable protocol and transmitting the indicator may include sending the message directly to one or more devices, broadcasting the message, or otherwise sending the message for receipt by other devices. An indicator may be received directly and/or accessed (e.g., read from a database) by a device. When received or accessed, an indicator may cause the receiving/accessing device to automatically perform one or more processes. For example, in certain cases, receiving an indicator may cause the receiving device to automatically control operation of one or more pieces of equipment in communication with the receiving device. In other cases, receiving an indicator may cause the receiving device to update a display, a user interface, or other output modality to communicate information to a user of the receiving device. FIG.14describes the application of fracture monitoring system1210in measuring interactions between fractures and monitor well1202after fluid1250has become substantially isothermal with subsurface formation1252. However, similar techniques may also be used to identify fracture interactions while fluid1250is undergoing heating by subsurface formation1252and has not yet become isothermal with subsurface formation1252. For example, prior to initiating fracturing of the target well and during heating of fluid1250, fracture monitoring system1210may obtain measurements for one or more flow attributes as fluid exits wellbore1206through fracture monitoring system1210. Such measurements may be used to establish trends in the flow attribute and associate those trends with thermal changes. For example, as fluid1250is warmed by subsurface formation1252, flow rate or flow volume for any given period in which pressure control valve1216is open may decrease over time. As another example, the time between flow events (i.e., the time between pressure control valve1216opening) may increase and/or the duration of flow events (i.e., the time pressure control valve1216remains open) may decrease. With the foregoing in mind, fracture monitoring system1210may be configured to determine when one or more measurements obtained during a fracturing operation are inconsistent with previously observed trends. For example, during fracturing, fracture monitoring system1210may determine that pressure control valve1216opened to permit flow before predicted by the thermally induced trend. As another example, fracture monitoring system1210may determine that a given period of flow lasted longer or produced greater flow volume than predicted by the thermally induced trend. In each of the foregoing examples, deviation from the corresponding thermally induced trend may generally indicate that the cause is something other than thermal expansion within monitor well1202. Accordingly, even though fluid1250may not be isothermal with subsurface formation1252, fracture monitoring system1210may nevertheless distinguish between thermally induced pressure changes/flow from monitor well1202and pressure changes/flow resulting from other causes, such as fracture interactions. As a result, fracture monitoring system1210can be used to monitor fracture propagation without necessarily waiting for fluid1250to become isothermal with subsurface formation1252. FIG.15is a flow chart illustrating a method1500of monitoring fracturing operations according to the present disclosure. The following discussion regarding method1500refers to well environment1200and elements thereof; however, any references to specific elements are intended to be illustrative only and implementations of method1500are not limited to the specific environment illustrated inFIG.12. At operation1502, controller1220obtains a baseline flow attribute value for portions of fluid1250exiting monitor well1202. As discussed in the context ofFIGS.13and14, the baseline flow attribute value may correspond to flow exiting monitor well1202in response to thermally induced pressure increases of fluid1250that cause fluid1250within monitor well1202to exceed a cracking pressure of pressure control valve1216. When such pressure increases occur, a portion of fluid1250exits monitor well1202via fracture monitoring system1210and, as a result, is measureable by flow meter1214. Controller1220(or a similar computing device) may then receive such measurements from flow meter1214and compute attributes of the flow. In certain implementations, controller1220may generate the baseline flow attribute value from a statistical analysis (e.g., an average, a median, etc.) of the multiple measurements. In other implementations, controller1220may access or otherwise obtain values corresponding to fracture-induced flow through fracture monitoring system1210. For example, controller1220may receive ranges, thresholds, or similar values from a well control/monitoring system that may be used to differentiate thermally induced flow from fracture-induced flow from monitor well1202. The flow attribute of interest may vary in applications of the present disclosure. For example, in certain implementations, the flow attribute may be a flow rate (e.g., in cubic centimeters per minute), a flow volume (e.g., in cubic centimeters), a change in flow rate, or similar flow attribute for a given portion of fluid1250exiting monitor well1202. In still other implementations, the flow attribute may be based on relationships between flow events. For example, the flow attribute may be a frequency of flow through fracture monitoring system1210(e.g.,1flow event per hour), a period between flow events (e.g., 2 hours between flow events), a change between flow events (e.g., an absolute or relative increase in flow volume between flow events), or any other similar measurement. Regardless of the attribute, the baselining step of operation1502may generally occur before initiating a fracturing operation at a target well or other operations within subsurface formation1252. By doing so, the baseline flow attribute value (or values) substantially correspond to thermally induced flow and may be used to isolate and differentiate thermally induced flow from other causes of flow, such as interactions with fractures of target wells. At operation1504, flow meter1214measures flow of fluid1250from monitor well1202during a fracturing operation at a target well. As noted in the context ofFIGS.12-14, flow meter1214obtains such measurement while pressure control valve1216controls pressure within monitor well1202or is otherwise opened or closed based on pressure in the well. Operation1504may further include flow meter1214transmitting the obtained measurement to controller1220, which may then process the measurement to generate a value corresponding to the flow attribute of the baseline measurement obtained in operation1502. Notably, flow from monitor well1202may be relatively small, regardless of whether it is caused by thermal changes in monitor well1202or interactions with fractures from a target well. For example, during testing, flow rates changed by less than 100 cc/min between thermally induced and fracture-induced flow from monitor well1202. Accordingly, flow meter1214may generally be selected to measure relatively low flow rates. Moreover, flow meter1214may also be selected to have appropriate sensitivity and accuracy to measure relatively small changes in flow through fracture monitoring system1210. For example, in certain implementations, flow meter1214may be a Coriolis flow meter with capable of accurately measuring flow rates below 10 gallons per hour and, in certain implementations, below 5 gallons per hour. Nevertheless, implementations of the present disclosure are not limited to any specific flow meters and any suitable flow meter may be used in fracture monitoring system1210. For example, and without limitation, flow meter1214may be any of a Coriolis meter, a differential pressure meter, a magnetic meter, a turbine meter, an ultrasonic meter, or a vortex meter. At operation1506, controller1220evaluates whether the measurement obtained in operation1504indicates interaction between monitor well1202and a fracture extending from a target well. To do so, controller1220generally compares the measurement/value obtained in operation1504to the baseline measurement/value obtained in operation1502(or similar values, thresholds, etc. obtained by controller1220). If controller1220determines that the measurement/value obtained during operation1504indicates thermally induced flow, fracture monitoring system1210may continue monitoring flow from monitor well1202(e.g., by repeating operation1504) and evaluating subsequent flow events to see if they also indicate thermally induced flow. In contrast, if controller1220determines that the measurement/value obtained in operation1504is different from values for thermally induced flow, is outside of an expected range, or meets other criteria indicating non-thermally induced flow, controller1220may transmit a corresponding indicator, as provided in operation1508. In certain implementations, the indicator may be received by a well control/monitoring system, which may then generate and transmit a corresponding alert/alarm to well personnel, automatically modify fracturing operation parameters (e.g., by selectively activating/deactivating certain pieces of well equipment), or perform other, similar operations. Implementations of the present disclosure may include fracturing operations involving multiple wells. For example, well completion may include fracturing multiple wells within a given subsurface formation. When fracturing multiple wells in a formation, stages of a first well may be alternatingly fractured with stages of a second well. This process is generally referred to as “zippering” or “zipper fracturing”. At least one advantage of a zipper fracturing is that operators can perform certain operations on wells in parallel. For example, while a stage of the first well is undergoing a first fracturing operation, operators can plug and perforate a stage of the second well in preparation for a second fracturing operation. When the first fracturing operation is completed, the second fracturing operation can begin relatively soon thereafter, and operators can begin preparing a subsequent stage of the first well for fracturing (e.g., by plugging and perforating the first well) while the second well is fractured. Considering the foregoing, implementations of the present disclosure may further provide improvements to zipper fracturing operations by using wells being fractured as monitor wells. For example, while a stage of a first well is subject to a fracturing operation, an operator may use an unperforated portion of a second well to monitor fracture propagation from the first well using the techniques and systems discussed herein. Subsequently, the operator may plug or otherwise isolate the fractured stage of the first well and use an uphole, unperforated portion of the first well to monitor fractures propagating from the second well during a subsequent fracturing operation performed on a stage of the second well. The fractured portion of the second well may then be plugged and isolated such that the second well may again be used to monitor fracture propagation from the first well. This process may continue until all required stages of both the first and second wells are fractured. In other implementations, only one well in a zipper fracturing operation may be used as a monitor well. For example, an unperforated first well may be used to monitor fracture propagation from a stage of a second well. Subsequently, a stage of the first well may be fractured. Each of the fractured stages of the first and second wells may then be plugged or otherwise isolated and the process repeated for subsequent stages of the wells. Accordingly, the first well is repeatedly used as a monitor well for the second well during the process of fracturing and completing both wells. Regardless of the specific order and sequencing of fracturing, the well used as a monitor well may include a fracture monitoring system, as described herein, to monitor fracture propagation from another well or wells. As previously discussed, such systems may be included in or otherwise coupled to a wellhead of the first well or the second well. When a well is used to monitor fractures, the casing, the pressure control valve of the fracture monitoring system, and any downhole plugs, etc. used to isolate previously fractured sections of the well, generally define an uphole monitoring portion of the well for use in monitoring fracture propagation from the other well. As described herein, while pressure within the monitoring portion is below a cracking/set pressure of the pressure control valve, the uphole monitoring portion remains substantially sealed. When pressure increases within the uphole monitoring portion, the pressure control valve opens, unsealing the wellbore and permitting fluid to flow from the wellbore. As described herein, one or more attributes of flow exiting the wellbore may be used to distinguish thermally induced from fracture-induced flow from the wellbore. Generally, an operator or control system may interpret detection of fracture interaction by fracture monitoring system according to the present disclosure as indicating that a fracturing operation or a phase of a fracturing operation is complete. Stated differently, detection of fracture interaction by a fracture monitoring system provides a rapid and accurate way of determining when fractures have sufficiently propagated through a subsurface formation and when corresponding fracturing operations may be halted or modified. As a result, a fracture monitoring system may help to avoid unnecessary “over fracturing” or overdesigning of a fracturing operation to account for potential variability in the subsurface formation, etc. As a result, a fracture monitoring system may reduce costs, time, and other resources required to performing a fracturing operation. In the specific context of a zipper fracturing operation, detection of fracture interactions by a fracture monitoring system may be used to signal when an operator may move on to the next phase of the fracturing operation. For example, when a first well is used as a monitor well and a fracturing operation is conducted in a second well, detection of fracture interactions using a fracture monitoring system of the first well may be used to accurately determine when the fracture operation in the second well is complete. Completion of the fracturing operation in the second well may, in turn, signal when preparation of the first well for fracturing and preparation of the second well for monitoring may begin. As a result, the zipper fracturing operation may progress to completion with relatively low risk that a well stage will be inadequately fractured, low down time between fracturing operations, and substantially eliminating the time, costs, etc. associated with over fracturing or overdesigning a fracturing operation. FIGS.16A-Fillustrate the general process of a zipper fracturing operation according to the present disclosure. Referring first toFIG.16A, a well environment1600is provided that includes a first well1602A and a second well1602B. First well1602A includes a casing1604A extending through a subsurface formation1652and defining a wellbore1606A. First well1602A is capped with a wellhead1608A, which includes a fracture monitoring system1210A. Second well1602B similarly includes a casing1604B extending through subsurface formation1652and defining a wellbore1606B. Second well1602B is also capped with a wellhead1608B, which includes a fracture monitoring system1210B. Each of wellhead1608A and wellhead1608B are in communication with a fracturing fluid delivery system1660, which is illustrated as including a pumping system1662and a fracturing fluid source1664. Implementations of the present disclosure are not limited to any specific arrangement of pumping system1662; however, in at least certain implementations, pumping system1662may be in the form of one or more fracturing fluid pump trucks. Fracture monitoring system1210A, fracture monitoring system1210B, and fracturing fluid source1664are also each shown as being communicatively coupled to a well control system1666. FIG.16Aillustrates well environment1600after fracturing of an initial stage of second well1602B while using first well1602A as a monitor well. As illustrated, when fracturing a stage of second well1602B, pumping system1662(or a flow control system between pumping system1662and first well1602A and second well1602B) may be configured to deliver fracturing fluid to wellbore1606B. As further illustrated inFIG.16A, wellhead1608A and fracture monitoring system1610A are configured to direct fluid from wellbore1606A through fracture monitoring system1610A. As discussed herein, such fluid may exit wellbore1606A in at least two scenarios. First, fluid within wellbore1606A may gradually increase in temperature and pressure because of heat transferred to the fluid from subsurface formation1652. Such pressure increases may result in a pressure control valve of fracture monitoring system1610A opening and allowing a volume of fluid to exit wellbore1606A. Fluid may also be forced out of wellbore1606A in response to interactions between wellbore1606A and fractures extending from second well1602B, such as fractures1670B. As discussed in the context ofFIGS.12-15, fracture monitoring system1610A may be configured to control pressure within wellbore1606A, to measure fluid exiting wellbore1606A, and to determine whether such flow is the result of thermal expansion of fluid within wellbore1606A or interactions with fractures1670B. To the extent fracture monitoring system1610A determines changes are the result of interactions with fractures1670B, fracture monitoring system1610A may transmit a corresponding indicator for receipt and processing by well control system1666, which may take appropriate action (e.g., stopping or modifying operation of fracturing fluid delivery system1660, issuing an alert/alarm, etc.). Wellhead1608B similarly includes or is coupled to a fracture monitoring system1610B. However, during fracturing of wellbore1606B, fracture monitoring system1610B may be closed/blocked to prevent fluid flow through fracture monitoring system1610B. Notably, fracture monitoring system1610B may be substantially blocked such that the pressure control valve of fracture monitoring system1210B does not open in response to elevated pressures within wellbore1606B caused during fracturing of wellbore1606B. Referring next toFIG.16B, well environment1600is illustrated after fracturing of wellbore1606A and plugging of wellbore1606B. More specifically, after wellbore1606A detects fracture propagation from a first stage of wellbore1606B, an operator may perform a fracturing operation on a corresponding stage of wellbore1606A, as illustrated by fractures1670A. For example, after fracturing wellbore1606B, the operator may fracture a stage of wellbore1606A by first perforating the stage and then injecting fluid from fracturing fluid delivery system1660to propagate fractures1670A from the perforations. During fracturing of wellbore1606A, wellhead1608A or fracture monitoring system1610A may be configured to substantially block fluid from passing through fracture monitoring system1610A such that the pressure control valve of fracture monitoring system1610A does not impact fracturing of wellbore1606A. While wellbore1606A is fractured, an operator may perform a plugging or similar isolation process in wellbore1606B, e.g., by installing plug1680B. Installation of plug1680B isolates an uphole portion1690B of wellbore1606B, thereby permitting uphole portion1690B to be used to monitor subsequent fracturing operations conducted on wellbore1606A. To further prepare uphole portion1690B, wellhead1608B and fracture monitoring system1610B may be configured to permit flow through fracture monitoring system1610B. More specifically, fracture monitoring system1610B may be configured such that the pressure control valve of fracture monitoring system1610B selectively permits fluid to flow through fracture monitoring system1610B when pressure within wellbore1606B exceeds a cracking pressure of the pressure control valve. The flow meter of fracture monitoring system1610B may also measure flow exiting wellbore1606B during this time to establish a baseline measurement for later distinguishing thermally induced flow from wellbore1606B from that induced by interactions between uphole portion1690B and fractures extending from wellhead1608A. Notably, in the specific example ofFIG.16A-F, formation of fractures1670A from1606A occurs without monitoring by wellbore1606B. However, in alternative implementations, plugging/isolation of1606B to create uphole portion1690B may be conducted prior to initiating formation of fractures1670A such that uphole portion1690B may be used to monitor propagation of fractures1670A. FIG.16Cillustrates a subsequent fracturing operation performed on wellbore1606A, assuming that uphole portion1690B has not been used to monitor for other fractures from wellbore1606A. More specifically, following propagation of fractures1670A, the corresponding stage of wellbore1606A may be plugged/isolated, e.g., using a plug1680A. The resulting uphole section1690A may then be perforated and fractured, forming fractures1672A. As noted above, during formation of fractures1672A, uphole portion1690B of wellbore1606B is generally configured to act as a monitor well. Stated differently, fracture monitoring system1610B is configured to control pressure within uphole portion1690B and to measure flow through fracture monitoring system1610B resulting from pressure changes within wellbore1606B. Fracture monitoring system1610B is further configured to distinguish between flow resulting from heating of fluid within wellbore1606B and flow resulting from interactions between fractures1672A and uphole portion1690B and to transmit an indicator to well control system1666when fracture-induced flow is detected. FIGS.16D-Fillustrate subsequent stages of the zipper fracturing operation. More specifically,FIG.16Dillustrates a subsequent fracturing operation conducted on wellbore1606B. More specifically, following fracturing of wellbore1606A, as illustrated inFIG.16C, an operator may perforate and fracture uphole portion1690B of wellbore1606B, as indicated by fractures1672B. During this fracturing operation, a plug1682A may be installed in wellbore1606A, thereby isolating the previously fractured stage and creating an uphole section1692A isolated from each of fractures1670A and fractures1672A and that may be used to monitor fracturing operations conducted in wellbore1606B. FIG.16Eillustrates a subsequent step in the zipper fracturing operation in which a plug1682B is installed in wellbore1606B, defining an uphole section1692B. As illustrated, uphole section1692B may then be perforated and fractured, relying on uphole section1692A to monitor the fracturing operations as discussed herein. Subsequently, and as illustrated inFIG.16F, a plug1684B may be installed in second well1602B and a subsequent fracturing operation may be conducted on uphole section1692A. The foregoing process may be repeated for as many stages as necessary to complete first well1602A and second well1602B. Although first well1602A and second well1602B are illustrated inFIGS.16A-Fas being vertical and substantially parallel, implementations of the present disclosure are not limited to such arrangements. Rather, first well1602A and second well1602B may have any suitable orientation provided that fractures from first well first well1602A are directed toward monitoring portions of second well1602B and fractures from second well1602B are directed toward monitoring portions of first well1602A. Moreover, whileFIGS.16A-Fgenerally illustrate a zipper operation including two wells, the foregoing concepts may be expanded to facilitate fracturing of any suitable number of wells extending through subsurface formation1652. FIGS.17A and17Bare a flow chart illustrating a method1700of fracturing multiple wells in a formation, such as in a zipper fracturing operation. In particular, the method1700includes fracturing of two wells within a subsurface formation. During fracturing of one well the other well (or a portion of the other well) is used to monitor fracture propagation from the well undergoing fracturing. Following fracturing, the well is prepared (e.g., plugged/isolated) for use as a monitor well during subsequent fracturing of a stage of the other well that previously acted as the monitor well. This process may be repeated, with each well alternating between having a stage fractured and acting as a monitor well during fracturing of the other well. Notably, each of the wells in method1700includes a fracture monitoring system (like fracture monitoring system1610A or fracture monitoring system1610B), for flow-based monitoring/detection of fracture propagation. Among other things, implementation of fracture monitoring systems according to the present disclosure may improve the effectiveness and efficiency of zipper fracturing operations. For example, fracture monitoring systems according to the present disclosure may allow operators to accurately identify fracture propagation during zipper fracturing operations by minimizing false positives that may result from thermally induced pressure changes. As another example, fracture monitoring systems according to the present disclosure may also permit monitoring without waiting for fluid in the well acting as the monitor well to become substantially isothermal with the surrounding formation. As a result, time between fracturing of stages can be significantly reduced, improving the overall speed of the zipper fracturing operation and reducing necessary costs and resources. Although not limited to the implementation illustrated inFIGS.16A-F, method1700is generally described below with reference to certain elements of well environment1600for clarity. Method1700assumes that each of first well1602A and second well1602B extend through subsurface formation1652, that first well1602A includes wellhead1608A in communication with fracture monitoring system1610A, and that second well1602B includes wellhead1608B in communication with fracture monitoring system1610B. Method1700also assumes that an initial fracturing operation is to be performed on a first stage of second well1602B with first well1602A acting as a monitor well and with the first stage of second well1602B already perforated. At operation1702, fracture monitoring system1610A obtains a baseline flow attribute value. The baseline flow attribute value is generally obtained prior to initiating a fracturing in second well1602B and, as a result, generally corresponds to a measurement of the flow attribute resulting from thermal expansion within first well1602A. As previously noted in the context of method1500, fracture monitoring system1610A may alternatively receive a range, value, threshold, etc. for use in distinguishing thermal from fracture-induced flow from wellbore1606A. At operation1704and during fracturing of the first stage of second well1602B, fracture monitoring system1610A obtains values/measurements of the flow attribute for flow from first well1602A (e.g., using a flow meter of fracture monitoring system1610A). At operation1706, a controller of fracture monitoring system1610A or similar computing device determines whether the measurements obtained in operation1704are indicative of interaction between fractures extending form the first stage of second well1602B and first well1602A. For example, the controller may compare the values/measurements obtained in operation1704with the baseline measurements (or other values, thresholds, ranges, etc.) obtained in operation1702. Until the controller determines that the values/measurements obtained in operation1704are substantially like the baseline values obtained in operation1702(e.g., indicating strong likelihood of thermally induced flow), operation1704and operation1706may be repeated for additional values/measurements of the attribute. On the other hand, when the controller determines that a substantial change in the flow attribute has occurred, the controller may transmit an indicator (operation1708). In certain implementations, when the indicator is received by a well monitor/control system, the well monitoring/control system may generate an alert, alarm, or similar message notifying personnel/operators that the fracture from the first stage of second well1602B has interacted with first well1602A. In addition, or alternatively, the well monitoring/control system may initiate one or more processes, including, but not limited to stopping injection of fracturing fluid into second well1602B (operation1710). At operation1712, each of first well1602A and second well1602B are prepared for fracturing a first stage of first well1602A. For example, an operator may perforate a location of first well1602A corresponding to the first stage of first well1602A. The operator may also install a plug or otherwise isolate the first stage of second well1602B such that an uphole portion of second well1602B becomes suitable for monitoring fracture propagation from the first stage of first well1602A. Preparation of first well1602A and second well1602B may also include reconfiguring fluid distribution systems, wellhead1608A, fracture monitoring system1610A, wellhead1608B, fracture monitoring system1610B, and the like to permit injection of fracturing fluid from fracturing fluid delivery system1660into first well1602A and to reconfigure second well1602B to act as a monitoring well. At operation1714, fracture monitoring system1610B obtains a baseline flow attribute measurement. The baseline flow attribute measurement is generally obtained prior to initiating injection of fracturing fluid to fracture the first stage first well1602A and, as a result, generally corresponds to a measurement of the flow attribute resulting from thermal expansion within second well1602B. At operation1716and during injection of fracturing fluid to fracture the first stage of first well1602A, fracture monitoring system1610B obtains values/measurements of the flow attribute for flow from second well1602B (e.g., using a flow meter of fracture monitoring system1610B). At operation1718, a controller of fracture monitoring system1610B or similar computing device determines whether the measurements obtained in operation1718are indicative of interaction between fractures extending form the first stage of first well1602A and second well1602B. Until the controller determines that the values/measurements obtained in operation1706are substantially like the baseline values obtained in operation251(e.g., indicating strong likelihood of thermally induced flow), operation1718and operation1720may be repeated for additional values/measurements of the attribute. On the other hand, when the controller determines that a substantial change in the flow attributed has occurred, the controller may transmit an indicator (operation1720) like that transmitted in operation1710and which may be received by a well monitoring/control system. Subsequently, an operator of the well monitoring/control system may stop injection of fracturing fluid into first well1602A (operation1722). Following operation1722, each of first well1602A and second well1602B may be prepared for fracturing a second stage of second well1602B. For example, an operator may perforate a location of second well1602B corresponding to the first stage of second well1602B. The operator may also install a plug or otherwise isolate the first stage of first well1602A such that an uphole portion of first well1602A becomes suitable for monitoring fracture propagation from the second stage of second well1602B. As discussed herein, preparation of first well1602A and second well1602B may also include additional steps to reconfigure various components illustrated in well environment1600for injection of fracturing fluid into second well1602B and to reconfigure first well1602A for use as a monitoring well during fracturing of the second stage of second well1602B. The general process illustrated inFIGS.17A and17Bmay continue to be repeated, alternating between fracturing a stage of first well1602A while second well1602B is used to monitor fracture propagation and fracturing a stage of second well1602B while first well1602A is used to monitor fracture propagation, with appropriate preparation of first well1602A and second well1602B (e.g., installation of plugs, reconfiguration of flow systems, reconfiguration of fracture monitoring systems, etc.) occurring between each fracturing operation. Referring toFIG.18, a detailed description of an example computing system1800having one or more computing units that may implement various systems and methods discussed herein is provided. It will be appreciated that specific implementations of these devices may be of differing possible specific computing architectures not all of which are specifically discussed herein but will be understood by those of ordinary skill in the art. The computing system1800is generally configured to receive and process pressure measurement data from a pressure transducer or similar sensor associated with the monitor well, such as the monitor well122shown inFIG.1(or any other monitor well discussed herein). Processing of pressure measurement data from the monitor well122may include, without limitation, performing one or more calculations on the pressure measurement data, transmitting the pressure measurement data, storing the pressure measurement data, formatting the pressure measurement data, displaying the pressure measurement data or data derived therefrom, and generating or suggesting control signals in response to the pressure measurement data. In one implementation, for example, the computing system1800is communicatively coupled to the pumping system132and is configured to generate and send control signals to the pumping system132to adjust the properties of the fracturing fluid provided by the pumping system132. The computing system1800may be a computing system capable of executing a computer program product to execute a computer process. Data and program files may be input to the computing system1800, which reads the files and executes the programs therein. Some of the elements of the computing system1800are shown inFIG.18, including one or more hardware processors1802, one or more data storage devices1804, one or more memory devices1806, and/or one or more ports1808-1812. Additionally, other elements that will be recognized by those skilled in the art may be included in the computing system1800but are not explicitly depicted inFIG.18or discussed further herein. Various elements of the computing system1800may communicate with one another by way of one or more communication buses, point-to-point communication paths, or other communication means not explicitly depicted inFIG.18. The processor1802may include, for example, one or more of a central processing unit (CPU), a graphics processing unit (GPU), an application specific integrated circuit (ASIC), a tensor processing unit (TPU), an a artificial intelligence (AI) processor, a microprocessor, a microcontroller, a digital signal processor (DSP), and/or one or more internal levels of cache. There may be one or more processors1802, such that the processor1802comprises a single central-processing unit, or a plurality of processing units capable of executing instructions and performing operations in parallel with each other, commonly referred to as a parallel processing environment. The computing system1800may be a conventional computer, a distributed computer, or any other type of computer, such as one or more external computers made available via a cloud computing architecture. The presently described technology is optionally implemented in software stored on the data stored device(s)1804, stored on the memory device(s)1806, and/or communicated via one or more of the ports1808-1812, thereby transforming the computing system1800inFIG.18to a special purpose machine for implementing the operations described herein. Examples of the computing system1800include personal computers, terminals, workstations, clusters, nodes, mobile phones, tablets, laptops, personal computers, multimedia consoles, gaming consoles, set top boxes, and the like. The one or more data storage devices1804may include any non-volatile data storage device capable of storing data generated or employed within the computing system1800, such as computer executable instructions for performing a computer process, which may include instructions of both application programs and an operating system (OS) that manages the various components of the computing system1800. The data storage devices1804may include, without limitation, magnetic disk drives, optical disk drives, solid state drives (SSDs), flash drives, and the like. The data storage devices1804may include removable data storage media, non-removable data storage media, and/or external storage devices made available via a wired or wireless network architecture with such computer program products, including one or more database management products, web server products, application server products, and/or other additional software components. Examples of removable data storage media include Compact Disc Read-Only Memory (CD-ROM), Digital Versatile Disc Read-Only Memory (DVD-ROM), magneto-optical disks, flash drives, and the like. Examples of non-removable data storage media include internal magnetic hard disks, SSDs, and the like. The one or more memory devices1806may include volatile memory (e.g., dynamic random access memory (DRAM), static random access memory (SRAM), etc.) and/or non-volatile memory (e.g., read-only memory (ROM), flash memory, etc.). Computer program products containing mechanisms to effectuate the systems and methods in accordance with the presently described technology may reside in the data storage devices1804and/or the memory devices1806, which may be referred to as machine-readable media. It will be appreciated that machine-readable media may include any tangible non-transitory medium that is capable of storing or encoding instructions to perform any one or more of the operations of the present disclosure for execution by a machine or that is capable of storing or encoding data structures and/or modules utilized by or associated with such instructions. Machine-readable media may include a single medium or multiple media (e.g., a centralized or distributed database, and/or associated caches and servers) that store the one or more executable instructions or data structures. In some implementations, the computing system1800includes one or more ports, such as an input/output (I/O) port1808, a communication port1810, and a sub-systems port1812, for communicating with other computing, network, or vehicle devices. It will be appreciated that the ports1808-1812may be combined or separate and that more or fewer ports may be included in the computing system1800. The I/O port1808may be connected to an I/O device, or other device, by which information is input to or output from the computing system1800. Such I/O devices may include, without limitation, one or more input devices, output devices, and/or environment transducer devices. In one implementation, the input devices convert a human-generated signal, such as, human voice, physical movement, physical touch or pressure, and/or the like, into electrical signals as input data into the computing system1800via the I/O port1808. Similarly, the output devices may convert electrical signals received from the computing system1800via the I/O port1808into signals that may be sensed as output by a human, such as sound, light, and/or touch. The input device may be an alphanumeric input device, including alphanumeric and other keys for communicating information and/or command selections to the processor1802via the I/O port1808. The input device may be another type of user input device including, but not limited to: direction and selection control devices, such as a mouse, a trackball, cursor direction keys, a joystick, and/or a wheel; one or more sensors, such as a camera, a microphone, a positional sensor, an orientation sensor, a gravitational sensor, an inertial sensor, and/or an accelerometer; and/or a touch-sensitive display screen (“touchscreen”). The output devices may include, without limitation, a display, a touchscreen, a speaker, a tactile and/or haptic output device, and/or the like. In some implementations, the input device and the output device may be the same device, for example, in the case of a touchscreen. The environment transducer devices convert one form of energy or signal into another for input into or output from the computing system1800via the I/O port1808. For example, an electrical signal generated within the computing system1800may be converted to another type of signal, and/or vice-versa. In one implementation, the environment transducer devices sense characteristics or aspects of an environment local to or remote from the computing system1800, such as, light, sound, temperature, pressure, magnetic field, electric field, chemical properties, physical movement, orientation, acceleration, gravity, and/or the like. Further, the environment transducer devices may generate signals to impose some effect on the environment either local to or remote from the computing system1800, such as, physical movement of some object (e.g., a mechanical actuator), heating or cooling of a substance, adding a chemical substance, and/or the like. In one implementation, a communication port1810is connected to a network by way of which the computing system1800may receive network data useful in executing the methods and systems set out herein as well as transmitting information and network configuration changes determined thereby. Stated differently, the communication port1810connects the computing system1800to one or more communication interface devices configured to transmit and/or receive information between the computing system1800and other devices by way of one or more wired or wireless communication networks or connections. Examples of such networks or connections include, without limitation, Universal Serial Bus (USB), Ethernet, Wi-Fi, Bluetooth®, Near Field Communication (NFC), Long-Term Evolution (LTE), and so on. One or more such communication interface devices may be utilized via the communication port1810to communicate with one or more other machines, either directly over a point-to-point communication path, over a wide area network (WAN) (e.g., the Internet), over a local area network (LAN), over a cellular (e.g., third generation (3G) or fourth generation (4G)) network, or over another communication means including any existing or future protocols including, without limitation fifth generation (5G), mesh networks and distributed networks. Further, the communication port1810may communicate with an antenna for electromagnetic signal transmission and/or reception. In certain implementations, the communication port1810is configured to communicate with one or more process control networks and/or process control devices including one or more of standalone, distributed, or remote/server-based control systems. In such implementations, the communication port1810is coupled to the process control networks and/or devices by a network, bus, hard-wire, or any other suitable connection. Such process control systems may include, without limitation, supervisory control and data acquisition (SCADA) systems and distributed control systems (DCSs) and may include one or more of programmable logic controllers (PLCs), programmable automation controllers (PACs), input/output (I/O) devices, human-machine interfaces (HMIs) and HMI workstations, servers, process historians, and other process control-related devices. Accordingly, the communication port1810facilitates communication between the computing system1800and process control equipment using one or more process-control related protocols including, without limitation, fieldbus, Ethernet fieldbus, Ethernet TCP/IP, Controller Area Network, ControlNet, DeviceNet, Highway Addressable Remote Transducer (HART) protocol, and OLE for Process Control (OPC), Wellsite Information Transfer Standard Markup Language (WITSML), and Universal File and Stream Loading (UFL). Computing system1800may include a sub-systems port1812for communicating with one or more external systems to control an operation of the external system and/or exchange information between the computing system1800and one or more sub-systems of the external system. In certain implementations, the sub-systems port1812is configured to communicate with sub-systems of a pump truck or similar vehicle configured to provide pressurized fracturing fluid to a well including, without limitation, sub-systems directed to controlling and monitoring pumps and associated pumping equipment. The system set forth inFIG.18is but one possible example of a computing system that may employ or be configured in accordance with aspects of the present disclosure. It will be appreciated that other non-transitory tangible computer-readable storage media storing computer-executable instructions for implementing the presently disclosed technology on a computing system may be utilized. In the present disclosure, the methods disclosed may be implemented, at least in part, as sets of instructions or software readable by a device. Further, it is understood that the specific order or hierarchy of steps in the methods disclosed are instances of example approaches. Based upon design preferences, it is understood that the specific order or hierarchy of steps in the method can be rearranged while remaining within the disclosed subject matter. The accompanying method claims present elements of the various steps in a sample order, and are not necessarily meant to be limited to the specific order or hierarchy presented. The described disclosure may be provided as a computer program product, or software, that may include a non-transitory machine-readable medium having stored thereon instructions, which may be used to program a computing system (or other electronic devices) to perform a process according to the present disclosure. A machine-readable medium includes any mechanism for storing information in a form (e.g., software, processing application) readable by a machine (e.g., a computer). The machine-readable medium may include, but is not limited to, magnetic storage medium, optical storage medium; magneto-optical storage medium, read only memory (ROM); random access memory (RAM); erasable programmable memory (e.g., EPROM and EEPROM); flash memory; or other types of medium suitable for storing electronic instructions. While the present disclosure has been described with reference to various implementations, it will be understood that these implementations are illustrative and that the scope of the present disclosure is not limited to them. Many variations, modifications, additions, and improvements are possible. More generally, embodiments in accordance with the present disclosure have been described in the context of particular implementations. Functionality may be separated or combined in blocks differently in various embodiments of the disclosure or described with different terminology. These and other variations, modifications, additions, and improvements may fall within the scope of the disclosure as defined in the claims that follow further below. It should be understood from the foregoing that, while particular embodiments have been illustrated and described, various modifications can be made thereto without departing from the spirit and scope of the invention as will be apparent to those skilled in the art. Such changes and modifications are within the scope and teachings of this invention as defined in the claims appended thereto. | 206,431 |
11859491 | DETAILED DESCRIPTION The following description of the exemplary embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. The following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims. The following embodiments are discussed, for simplicity, with regard to the terminology and structure of a water cut sensor. Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments. FIGS.1A and1Bare schematic diagrams of systems for determining water cut according to embodiments. The systems100A and100B include a water cut sensor102comprising a magnetoelastic ribbon104and an inductive coil106arranged proximate to the magnetoelastic ribbon104so that an electromagnetic field produced by the inductive coil106electromagnetically excites the magnetoelastic ribbon104. The proximate arrangement can involve the inductive coil106surrounding the magnetoelastic ribbon104(as illustrated inFIGS.1A and1B) or the inductive coil can be arranged adjacent to the magnetoelastic ribbon104. The systems also include an alternating current source108and a processor110configured to determine the water cut of the water/oil emulsion112based on a resonant frequency of the magnetoelastic ribbon104while the magnetoelastic ribbon104is excited by electromagnetic field produced by the inductive coil. A feed line114is coupled to the water cut sensor102. The feed line114includes an electrical coupling between the alternating current source108and the inductive coil106of the water cut sensor102. The feedline includes an electrical coupling between the processor110and the inductive coil106of the water cut sensor102(FIG.1A) or the processor110is coupled to an acoustic sensor118(FIG.1B). Those skilled in the art will recognize that an acoustic sensor refers to a structure comprising hardware for receiving acoustic waves and measuring the frequency of the received acoustic waves. As also illustrated inFIGS.1A and1B, a magnetic biasing ribbon116is arranged adjacent to the magnetoelastic ribbon104. The magnetic biasing ribbon116magnetizes the magnetoelastic ribbon, thereby reducing the required excitation field strength and increasing the impedance response in the inductive coil106. The water cut sensor102can be arranged in a housing that is lowered into the downhole. The housing protects the components of the water cut sensor102from being impinged upon by anything other than the water/oil emulsion because such an impingement can affect the resonant frequency of the magnetoelastic ribbon. As will be discussed in more detail below, the sensor102operates so that when it is immersed in a water/oil emulsion, the resonant frequency of the magnetoelastic ribbon104changes depending upon the water cut of the emulsion. This change in the resonant frequency of the magnetoelastic ribbon104in turn induces changes in the resonant frequency and vibration amplitude of the impedance of the inductive coil106. Thus, the water cut of a water/oil emulsion can be determined based on a resonant frequency of the magnetoelastic ribbon104, which in turn can be determined based on a measured shift in the resonant frequency and/or vibration amplitude of the impedance of the inductive coil106. Alternatively, the resonant frequency of the magnetoelastic ribbon104can be determined using an acoustic sensor, which measures sound waves generated by the magnetoelastic ribbon104. The processor110can be any type of processor suitable programmed to determine the resonant frequency or the vibration amplitude of the impedance of the inductive coil106in the manner described in more detail below. Thus, the processor110can be coupled to a memory that stores the programming for the processor. The memory can be integrated into the processor110or can be a separate memory. Further, the processor can include an integrated analog-to-digital converter to convert the analog measurements into a suitable digital form, or a separate analog-to-digital converter can be coupled between the processor110and the inductive coil106. The sensor102of the water cut system100was produced to evaluate its performance. The magnetoelastic ribbon104comprised an iron-based alloy, which during testing was the Ultra-Stripe® produced by Sensormatic, and had dimensions 36×6×0.028 mm3. The magnetic biasing ribbon116comprised iron and nickel and had dimensions of 30×6×0.05 mm3. The alternating current source108produced frequencies between 50 kHz and 62 kHz, which covered the relevant frequency range that included the resonance peak of 58 kHz of the magnetoelastic ribbon104. It should be recognized that the dimensions of the ribbons, resonant frequency, and frequency range mentioned above are provided as examples and that these ribbons can be employed with the disclosed embodiments having different dimensions, different resonant frequencies, and different frequency ranges. In general, a decrease in the ribbon geometry increases the ribbon resonant frequency and vice-versa. The impedance measured in the inductive coil106is affected by the magnetic susceptibility of the core materials, which includes the magnetoelastic ribbon104, the magnetic biasing ribbon116, and the water/oil emulsion. The impedance of the inductive coil is given as Z=R+jXL, where the reactance XL=ωL, and the inductance L of the coil can be written as: L=N2μ(f,η)Al(1) where N represents the amount of turns in the coil (350 in the tested system), l the length (12.6 m in the tested system) and A the cross-sectional area of the inductor (6 mm2in the tested system). Furthermore, the permeability of the core material (μ) is influenced by the water/oil liquid volume inside the sensor and the permeability of the magnetoelastic ribbon104and the magnetic biasing ribbon116. The change in core material permeability induced by changing the liquid from pure water to pure crude is significantly smaller than the fluctuations measured in the sensor material and therefore were ignored. The permeability of the magnetoelastic ribbon104is a function of frequency f and the surrounding medium's viscosity η through magnetostriction. Magnetoelastic vibrations in a magnetoelastic sensor occur, when the applied magnetic field is time varying in nature, causing the field-generated strain to vary with time; thus, producing a longitudinal elastic wave. These vibrations, in turn, generate a secondary magnetic field in the inductive coil that can be detected. The measured shift in resonant frequency and/or vibration amplitude of the impedance of the inductive coil is caused by a change in the material surrounding the magnetoelastic ribbon104, i.e., a change in the water cut of the water/oil emulsion in which the water cut sensor102is submerged. The resonant frequency of the magnetoelastic ribbon is determined by the effective damping force induced by the viscosity of the surrounding medium. Therefore, magnetoelastic ribbons in mediums of varying viscosity possess a significantly different characteristic frequency response. The impedance of the inductive coil with the amorphous and bias ribbons was measured for air, water and oil, the results of which are illustrated inFIG.2. As illustrated in the graph ofFIG.2, there was a reduction in resonant frequency and vibration amplitude from exposure in air to water of 0.99 kHz and 1.93 kΩ, respectively. Further reductions with exposure to oil were measured at 3.37 kHz and 0.4 kΩ from the measured peaks in water. Thus, the water cut sensor102exhibited amplitude changes of 75% and 90% when the water cut sensor102is loaded in water and oil respectively, compared to the water cut sensor when it is unloaded in air. Further, the water cut sensor102exhibited frequency changes of 0.46% and 3.88% when the water cut sensor102is loaded in water and oil respectively, compared to the water cut sensor when it is unloaded in air. With a measurement voltage of 10 mV, the power consumption was 40 nW in air. When immersed in the water/oil emulsion this value ranges from 160 nW to 500 nW. As will be appreciated, power consumption in these ranges characterizes the water cut sensor102as an ultra-low-power sensor. The water cut response of the water cut sensor102was further evaluated by immersing the sensor in water/oil emulsions having different water cuts and measuring the resonant frequency shift of the impedance of the inductive coil106, which provides both a resonant frequency and a vibration amplitude. Stable water/oil emulsions were created with 10% volumetric surfactant (Tween 20). Different magnetoelastic ribbons104were used with each of the different water cut emulsions, thereby ensuring that there were no liquids present on the surface of the magnetoelastic ribbon104before immersing it in a particular water/oil emulsion. Each magnetoelastic ribbon was characterized in air, where-after the frequency and impedance shifts were normalized to the frequency shift caused by 100% water. The results of this testing is illustrated in the graph ofFIG.3. As illustrated, as the water cut of the oil/water emulsion decreased, there was a decrease in resonant frequency (relative to an undamped sensor) of the inductive coil106. This is consistent with the following formula for calculating the relative change in resonant frequency: Δf=πfo2πρsdηρl(2) where ƒo, the resonant frequency of the ribbon in vacuum, ρsand d the density and thickness of the ribbon, respectively, and η and ρtthe effective dynamic viscosity and density of the surrounding medium, respectively. The frequency shift is proportional to the square root of the medium's viscosity and density product. These experimental results were consistent with the prediction models considered in the evaluation, which indicates that the evaluated sensor possessed a sensitivity to a reduction or increase of the density/viscosity product. The sensitivity was approximated as 27 Hz/% by fitting a linear function within the 90-10% WC range. These experimental results also support a determination that the water cut sensor is surrounded by an air/gas mixture when the resonant frequency is lower than a resonant frequency corresponding to 90% water cut. Because the water cut sensor102is designed to be used in very harsh conditions, sometimes with brine salinity ranging from thousands to 260,000 ppm, the magnetoelastic ribbon104and the magnetic biasing ribbon116can corrode, which can affect their magnetic properties. In order to avoid or minimize corrosion, the magnetoelastic ribbon104and the magnetic biasing ribbon116can be provided with a non-corrosive coating. For example, the magnetoelastic ribbon104and the magnetic biasing ribbon116can be dipped in a non-corrosive coating, such as polytetrafluoroethylene (PTFE) (known under the tradename Teflon®), parylene C, and the like. When the magnetoelastic ribbon104and the magnetic biasing ribbon116were dip coated in polytetrafluoroethylene, the ribbons were coated on both sides and the coating added approximately 2.5 μm in thickness to each ribbon. Thus, the tested magnetoelastic ribbon, including the coating, was only 28 μm thick. Testing with this coating showed that the saturation magnetization of the magnetoelastic ribbon104and the magnetic biasing ribbon116remained stable in air, water, and oil over twenty days of testing. The non-corrosive coating caused the resonant frequency of the magnetoelectric ribbon to drop by ˜3%, which is due to the mass loading the coating causes to the vibrating body. This value is near the theoretical value of 2.13%. With the coating applied, the resonant frequencies of the inductive coil106remained constant in air, water, and oil for an extended period of time. FIG.4is a flowchart of a method for determining water cut according to embodiments. A water cut sensor102is arranged in the water/oil emulsion112(step405). The water cut sensor102comprises a magnetoelastic ribbon104and an inductive coil106arranged proximate to the magnetoelastic ribbon104so that an electromagnetic field produced by the inductive coil106electromagnetically excites the magnetoelastic ribbon104. The magnetoelastic ribbon104is then electromagnetically excited by the electromagnetic field produced by the inductive coil106(step410). The water cut of the water/oil emulsion112is determined based on a resonant frequency of the magnetoelastic ribbon104while the inductive coil106is electromagnetically excited (step415). The resonant frequency of the magnetoelastic ribbon104can be detected electromagnetically or acoustically. Electromagnetically detecting the resonant frequency can be achieved by detecting the secondary magnetic field in the inductive coil106generated by vibrations of the magnetoelastic ribbon104. Acoustically detecting the resonant frequency can be achieved using an acoustic sensor to acoustically measure sound waves generated by the elastic vibrations in the magnetoelastic ribbon104. The determination of the water cut of the water/oil emulsion can involve determining the resonant frequency or vibration amplitude of the impedance of the inductive coil while the inductive coil is electromagnetically excited and identifying, using a table correlating resonant frequencies or vibration amplitudes of the impedance of the inductive coil and water cut, the water cut based on the determined resonant frequency or vibration amplitude of the impedance of the inductive coil. The resonant frequency and/or vibration amplitude is detected electromagnetically. The table correlating resonant frequencies or the vibration amplitudes of the impedance of the inductive coil and water cut is generated by exposing the water cut sensor to a plurality of water/oil emulsions having different water cuts, determining the resonant frequency or the vibration amplitude of the impedance of the inductive coil when the water cut sensor is exposed to the plurality of water/oil emulsions, and recording, in the table, the correlation between the resonant frequency or the vibration amplitude of the impedance of the inductive coil and the water cut of the corresponding one of the plurality of water/oil emulsions. Consistent with the graph inFIG.3, this can involve make a number of measurements using different water cuts (e.g., in increments of 10%) and then using a linear fit to the measurement results to generate values for water cuts that were not directly measured, e.g., 49%, etc. FIG.5is a flowchart of a method for producing a system for determining water cut according to embodiments. Initially, a water cut sensor102, which comprises a magnetoelastic ribbon104and an inductive coil106arranged proximate to the magnetoelastic ribbon104so that an electromagnetic field produced by the inductive coil electromagnetically excites the magnetoelastic ribbon, is provided (step505). The water cut sensor102is coupled to a feed line114(step510). An alternating current source108is coupled to the inductive coil106via the feed line114(step515). A processor110is coupled to the inductive coil106via the feedline114or is coupled to an acoustic sensor118(step520). The processor110is configured to determine the water cut of the water/oil emulsion112based on a resonant frequency of the magnetoelastic ribbon104. The method can further involve applying a protective coating on the magnetoelastic ribbon104, for example, by dipping the magnetoelastic ribbon104in Polytetrafluoroethylene, PTFE. The method can also involve arranging a magnetic biasing ribbon116adjacent to the magnetoelastic ribbon104. The method can further involve storing, in a memory associated with the processor110, a table correlating resonant frequencies or vibration amplitudes of the impedance of the inductive coil and water cut. The disclosed systems and methods for determining water cut are particularly advantageous because they provide a wireless capability and the ability to determine water cut with a very low power requirement. The wireless capability relates to the lack of contact between the inductive coil106and the magnetoelastic ribbon104. Thus, the magnetoelastic ribbon104can be located inside a liquid-filled chamber/enclosure and the excitation and detection of the resonant frequency of the magnetoelastic ribbon104can be achieved with a coil (and wires) outside of the liquid-filled chamber/enclosure. Further, in a wireless implementation the processor110, sensor102, and a battery power supply may be positioned downhole. Enclosing these components in an environmental condition-proof enclosure downhole allows for downhole sampling and logging of water cut data without the need to run communication wires down the bore. The disclosed systems and methods are ultra-low power due to the fact that these sensor102consumes a minimum power of, for example, 500 nW, which is an extremely low power consumption for a water cut detector. Even with the additional power requirements of the processor110and any necessary amplifier/filter circuits, the systems100A and100B can be implemented using a battery supply. The disclosed water cut sensor is scalable in size and, consequently, resonating frequency. Thus, it can be altered for a specific bore diameter or emulsion compositions, while avoiding frequency noise that may be present or providing multi-sensor encoded readout. The disclosed water cut sensor requires very little power, due to the low biasing field required to excite a signal from the sensor ribbon, which can be provided by an additional magnetized biasing ribbon. With a thickness of 28 μm the sensor ribbon is of very low mass and greatly affected by slight changes in surface damping caused by viscosity changes in the surrounding medium, making it adequately sensitive for water cut measurements. The disclosed water cut sensor can detect all three phases (i.e., gas, water, and oil) with amplitude changes of 75% and 99% and resonant frequency shifts of 0.46% and 3.88%, respectively, compared to the gas phase. The response of the sensor enables characterizing the water-cut range from 10%-90%. Further, the anti-corrosion coating prevents decay of the magnetic characteristics and ensures long-lasting performance of the water cut sensor. The disclosed embodiments provide a system for determining water cut of a water/oil emulsion. It should be understood that this description is not intended to limit the invention. On the contrary, the exemplary embodiments are intended to cover alternatives, modifications and equivalents, which are included in the spirit and scope of the invention as defined by the appended claims. Further, in the detailed description of the exemplary embodiments, numerous specific details are set forth in order to provide a comprehensive understanding of the claimed invention. However, one skilled in the art would understand that various embodiments may be practiced without such specific details. Although the features and elements of the present exemplary embodiments are described in the embodiments in particular combinations, each feature or element can be used alone without the other features and elements of the embodiments or in various combinations with or without other features and elements disclosed herein. This written description uses examples of the subject matter disclosed to enable any person skilled in the art to practice the same, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the subject matter is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims. | 20,246 |
11859492 | DETAILED DESCRIPTION In the following detailed description of embodiments of the disclosure, numerous specific details are set forth in order to provide a more thorough understanding of the disclosure. However, it will be apparent to one of ordinary skill in the art that the disclosure may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description. Throughout the application, ordinal numbers (e.g., first, second, third, etc.) may be used as an adjective for an element (i.e., any noun in the application). The use of ordinal numbers is not to imply or create any particular ordering of the elements nor to limit any element to being only a single element unless expressly disclosed, such as using the terms “before”, “after”, “single”, and other such terminology. Rather, the use of ordinal numbers is to distinguish between the elements. By way of an example, a first element is distinct from a second element, and the first element may encompass more than one element and succeed (or precede) the second element in an ordering of elements. FIG.1shows a well drilled formation (100) in accordance with one or more embodiments. The formation (100) embodies a drilled wellbore (103) and drill pipe (105). The formation (100) may be any geological formation from which drilling fluid such as oil or gas may be produced by drilling a wellbore and extracting the fluid from the formation. A wellbore may be any drilled hole used to extract hydrocarbons, gas, or water from the formation. In one or more embodiments, the formation (100) ofFIG.1has fractures. Fractures are separations or cracks in geological formations that divide one or more rocks. Fractures may be microfractures (101), natural fractures (104), or hydraulic fractures (102). Microfractures (101) may be openings created after hydraulic fracturing that are smaller than the hydraulic fractures (102). Hydraulic fractures (102) are fractures created after hydraulic fracturing of a well formation (100). Hydraulic fracturing operations result in micro fractures that are created around the hydraulic fractures in addition to the natural fractures that already exist in the formation (100). In one or more embodiments, channels are created by micro robots (i.e. Fracbots) to connect these separate types of fractures in a formation to boost the productivity of the formation and make it sustainable for longer time. WhileFIG.1depicts hydraulic fractures (102) as branches, those skilled in the art will appreciate that hydraulic fractures may have different geometries including but not limited to triangles, for example. FIGS.2and3show a hydraulic fracture from a wellbore (201) in accordance with one or more embodiments. Specifically, the hydraulic fracture (102) has a half-length (202). The half-length (202) of a fracture is the radial distance from the wellbore (201) to the outer tip of the fracture. A hydraulic fracture (102) may be any cracks in rock formations created by injection of pressurized liquid in the formation. The natural formation permeability dictates whether the hydraulic fracture will be connected to the micro fractures and natural fractures or not, which will affect the productivity of the well. The hydraulic fractures (102) may be held open by proppants such as sand once the hydraulic pressure is removed from the well. Although after placing the hydraulic fracture there is no way to ascertain the fracture geometry,FIGS.2and3are examples of the geometrical shape a hydraulic fracture (102) can take on. In one or more embodiments, proppant sized FracBots (discussed below inFIGS.4-9) are pumped at the tip of the fracture half length (XI) (202) as shown inFIGS.2and3. The FracBots may be placed at any pumping stage during fracturing operations or injection operations. In one or more embodiments, the FracBots may be retrieved after flow back when the FracBots are placed at the beginning of the fracture half length (Xf) (202). Flow back is the process of recovering fluid to the surface after being injected. In one or more embodiments, the FracBots may be placed at the beginning of the fracture half length (Xf) (202) by disposing them at a last pumping stage. The pumping stages may be estimated through simulation programs which depict different sizes of proppant and other factors. Other factors may include, but are not limited to, a type of formation (100), porosity, and permeability. In one or more embodiments, a FracBot is an automated mechanical device, or a robot, configured to activate upon entering any type of fracture in a formation in order to create one or more channels connecting existing fractures. As disclosed herein, there are two types of FracBots: a Frac Microbot and a Fracworm, each with different physical properties.FIGS.4-6and7-9discuss the Frac Microbot and the Fracworm, respectively. FIGS.4-6each show a dimensional drawing of a Frac Microbot (300). In one or more embodiments, the Frac Microbot (300) is a specific type of FracBot. The Frac Microbot (300) may have a smooth conical shape as shown, with no arms to help aid in movement of the Frac Microbot (300). In the example ofFIGS.4-6, the Frac Microbot (300) may have a conical shape with an indention in the middle where a spring (302) is disposed to help aid in movement of the Frac Mircobot (300). The spring (302) may be of any material and/or shape with the ability to store energy and release it. The spring creates a springing or jumping action to help move the Frac Microbot (300) within a fracture. In one or more embodiments, the Frac Microbot (300) has a drill bit (301) at the cone-shaped end of the Frac Microbot (300). The drill bit (301) rotates to drill the channels between existing fractures in the formation to connect the existing fractures. The drill bit (301) may be any tool of any size with a cutting ability to create holes or cut through formation. For example, the drill bit (301) may have the ability to rotate in a circular cross-section motion to create holes by removing material in the formation (100) in different materials downhole. The drill bit (301) may be of any type of material that can cut depending on the formation characteristics. Those skilled in the art will appreciate that the drill bit (301) of the Frac Microbot (300) may be smaller in size than a drill string drill bit to accommodate for the overall size of the Frac Microbot (300). The Fracbots (300,303) are proppant sized and are pumped downhole along with the proppant. Specifically, for example, the Frac Microbot (300) may have the dimensions in the range of 1.5 mm to 4 mm in length and 0.5 mm to 2 mm in width. Movement of the Frac Microbot may be facilitated in multiple ways. For example, movement of the Frac Microbot may be facilitated by vibrations from rotation of the drill bit (301) that may create a spiral movement, allowing the Frac Microbot (300) to move within or around a fracture. The vibrations may originate from the FracBot itself. The spring (302) may add to vibration movement through the springing or jumping action. FIGS.7-9show a dimensional drawings of a Fracworm (303), which is a specific type of FracBot. Specifically, the Fracworm embodies all ofFIGS.4-6of the Frac Microbot with an addition of movement arms (304) attached to the outside of the body. The movement arms (304) may be used to aid in movement of the Fracworm (303) within a formation fracture. Additionally, in one or more embodiments, the movement arms (304) facilitate anchoring of the Fracworm (303) to help with creating channels once the Fracworm is disposed within a fracture or at the end of a fracture. The movement arms may move by rotation, upward and downward “flapping” movement, in an “S” movement, or any other suitable movement to aid in overall Fracworm (303) movement. Alternatively, in one or more embodiments, the movement arms may not move themselves, but instead may be used to push the Fracworm (303) through the fractures in the formation. The movement arms (304) may be of any material that helps the Fracworm (303) anchor itself and move with the vibrations of the drill bit (301). The distribution of the movement arms (304) may be of any distance or number based on the type of formation or the design of the Fracworm. Each of the Fracbots (300,303) may include additional components in addition to the drill bit and spring, as shown inFIGS.5A and5Band discussed below. FIG.10depicts a formation (100) after hydraulic fracturing and usage of Fracbots (300,303) in accordance with one or more embodiments.FIG.10includes the fractures shown in inFIG.1and depicts the channels (404) created by the Fracbots (300,303) to connect the existing fractures. As discussed above, the Fracbot may be an automated robot used to create channels (404) between fractures. The channels (404) may connect pores in the formation to the wellbore as well as make connections between fractures. Considering the existence of a large number of random natural fractures (104) in some formations (100), there is not an effective way to model the shape and location of the fractures. For example, the hydraulic fractures (102) are branched from the wellbore (103) with natural fractures (104) and microfractures (101) distributed around the hydraulic fractures (102). The channels (404) created by the Fracbots (300,303) may start from the hydraulic fracture (102) and extend to one or more microfractures (101). Alternatively, the channels (404) may start from the natural fractures (104) and extend to one or more microfractures (101). AlthoughFIG.4depicts channels (404) connecting hydraulic fractures (401) to micro fractures (402) and natural fractures (403) as pathways, the channels (404) could move in a more sparse and random way without departing from the scope herein. FIGS.11and12show Fracbot flow diagrams and addition components of the Fracbots. More specifically,FIGS.11and12depict a flow from (A) to (B). (A) depicts a figure showing the Fracbot coated with a polymer. In one or more embodiments, each Fracbot is coated in polymer (502) or any other suitable coating material before it is disposed in the proppant and sent downhole to the formation fractures. The polymer coating dissolves at different temperatures dependent on the particular makeup of the polymer coatings. There may be different types of polymer coating recipes that dissolve at different temperatures and there are many already available in the industry. In this example, the polymer coating chosen is based on the necessity to dissolve under the specific reservoir temperature conditions. The polymer coating is used to protect the surface of the Fracbot and downhole equipment. The outer polymer coating dissolves due to temperature and reveals the components of the Fracbot shown in (B). The movement arms (304) may be of any length and diameter of 0.001% in comparison to the size of the Fracworm (303). Specifically, the polymer coating dissolves upon reaching a range of high temperatures downhole. In (B) ofFIG.11, the FracBot includes a drill bit (504), a rotary swivel (506) operatively connected to the drill bit (504), a battery (507) and e-ship (508) to power the motor (510) of the Fracbot, and a motor (510) that runs the drill bit (504). The FracBot is configured to send real-time pressure and temperature readings via a sensor on the FracBot.FIG.12includes all embodiments ofFIG.11with addition of the movement arms (512). The rotary swivel (506) is a precision component for the connection between stationary equipment and rotating parts. The battery (507) and e-ship (508) may be separate or together. In one or more embodiments, the e-ship (508) is an electronic chip that aids in the activation of the FracBots via, for example, a preprogramed timer or pre-set temperature. Typically, the initial temperature in the formation (100) is lower than the temperature after hydraulic fracturing operations are completed. Thee rise in temperature may be one activation method of dissolving the polymer (502) coating. The e-ship (508) includes the sensor needed to retrieve and send data. The sensor readings may be retrieved in real time or recovered by retrieving the FracBots. One way to retrieve the FracBot is through flow back. The battery (507) supplies power to the motor to set the FracBot in motion. The battery (507) may activate at the point of dissolvement of the polymer (502) coating. FracBots continue to move until the battery (507) life runs out. FIG.13shows a flowchart in accordance with one or more embodiments. Specifically, the flowchart illustrates a method for increasing flow in production from a formation using Fracbots (300,303). Further, one or more blocks inFIG.13may be performed by one or more components as described inFIGS.1-12. While the various blocks inFIG.13are presented and described sequentially, one of ordinary skill in the art will appreciate that some or all of the blocks may be executed in different orders, may be combined or omitted, and some or all of the blocks may be executed in parallel. Furthermore, the blocks may be performed actively or passively. Initially, one or more Fracbots (300,303) are pumped into the well formation (100) through a liquid (Block602). In this disclosure, the number of FracBots needed for a significant effect is hundreds. The amount of FracBots to be pumped depends on many factors which include, but are not limited to, rock permeability and formation type. The FracBots may be Frac MicroBots (300), Fracworms (303), or both. The liquid may be made a proppant or any type of liquid that can be pumped downhole and is capable of carrying the Fracbots (300,303) to an existing fracture half-life. The Fracbots may be pumped through tubing or casing. In Block604, the Fracbots are activated in the formation (100) when the polymer (502) coating of the robot dissolves when reaching a predetermined temperature. Once the Fracbots activate, their movement may be initiated by vibration of the drill bit or the motor (510) of the Fracbot. In Block606, Fracbots drill through the formation between existing fractures to create micro channels (404). In this case of a Fracworm, the Fracworm may anchor itself at a particular location at the end of or within an existing fracture using the movement arms of the Fracworm and then begin drilling the formation to create channels. The micro channels are used to connect existing fractures in the formation (100) thereby creating a path for fluid flow that did not exist among disjoint and disconnected hydraulic and/or natural fractures in the formation (Block608). Channels may be micro in size. Channels may be drilled from the body of the Fracbot or the drill bit (301) of the Fracbot. In the case of Fracworms, channels may also be drilled by the movement arms (304) of the Fracworm (303). In Block610, fluid is produced via a well from the fractures using the micro channels created by the Fracbots. Production from fractures and pores is well known in the industry as it is a common method of fluid extraction. Embodiments disclosed herein provide the ability to create channels to connect the hydraulic fractures with the micro fractures around it in addition to the natural fractures which boosts the productivity of the reservoir/formation and make it sustainable for longer time. It will also reduce the number of stages required to reach the required gas or oil rate. In addition, although not shown inFIG.13, the Fracbots send live pressure and temperature which can be used to enhance the fracturing design. While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims. | 16,038 |
11859493 | Numerals of the drawings are described as follows:1—pressure measuring segment;11—main pipe;11—oil inlet;112—external thread;113—internal thread;12—hydraulic bladder;13—fixing ring;14—barrier sheet;15—outer pillow housing;16—connection sleeve;2—connecting rod;3—hydraulic pump;4—pressure gauge;5—high-pressure oil pipe;6—pressure control valve;7—tray;8—push rod; and9—connection casing. DETAILED DESCRIPTION OF THE EMBODIMENTS As shown inFIGS.1-11, the present disclosure provides a device for monitoring a horizontal extrusion force of roof rock strata and a method using the same. Specific examples are described below. Specifically, a device for monitoring a horizontal extrusion force of roof rock strata includes a pressure measuring segment1, a connecting rod2, a hydraulic pump3, a pressure gauge4, a high-pressure oil pipe5, a pressure control valve6, a tray7, a push rod8and a connection casing9, as shown inFIG.1. The connecting rod2is thread-connected with the pressure measuring segment1, a front end of the push rod8is connected with the connecting rod2, the tray7is disposed at a rear end of the push rod8, the connection casing9is connected with the tray7, and the high-pressure oil pipe5is connected with the hydraulic pump3and protrudes to the pressure measuring segment1through inner cavities of the push rod8and the connecting rod2. The combination of the connecting rod2and the pressure measuring segment1facilitates monitoring the horizontal extraction forces at different depths, the push rod8ensures that the device can perform deep-hole monitoring, the tray7and the connection casing9facilitate fixing the device and placing the high-pressure oil pipe5in the borehole, the combination of the hydraulic pump3and the pressure gauge4facilitates real-time monitoring, and the hydraulic pump3, the pressure gauge4and the pressure control valve6may realize long-time monitoring of the horizontal extrusion force. By using the device, a plurality of pressure measuring segments may be disposed, and the connecting rods with an appropriate length may be selected according to the location of the monitoring point, so that each connected pressure measuring segment is disposed at the designated monitoring point, producing high accuracy. By using the device, the horizontal extrusion forces of several borehole depths may be monitored by disposing one borehole without mutual interference among monitorings of different pressure measuring segments. Specifically, the pressure measuring segment1includes a main pipe11, a hydraulic bladder12, a fixing ring13, a barrier sheet14, an outer pillow housing15and a connection sleeve16. As shown inFIGS.3-9, both ends of the hydraulic bladder12are sleeved on the main pipe11by the fixing rings13, and an oil inlet111is disposed on the main pipe11to be in communication with the hydraulic bladder12, and a sealing gasket may also be disposed between the fixing ring13and the main pipe11to ensure sealing of the hydraulic bladder12. The outer pillow housing15is sleeved on the main pipe11, the connection sleeve16is wrapped around an outer side of the outer pillow housing15, and the barrier sheet14is disposed between the fixing ring13and the outer pillow housing15. Under actions of the outer pillow housing15and the barrier sheet14, the hydraulic bladder12can only expand along a radial direction of the main pipe, and the connection sleeve16ensures that the outer pillow housing15can reset smoothly after use. One segment of high-pressure oil pipe5may also be fixedly disposed at the oil inlet of the pressure measuring segment1, and an oil pipe joint may be disposed on the high-pressure oil pipe5to facilitate mounting. A threaded segment of the main pipe11of the pressure measuring segment is exposed to facilitate rapid connection of the pressure measuring segment and the connecting rod. Each high-pressure oil pipe5is divided into a plurality of segments and the high-pressure oil pipes5are connected by oil pipe joints. One segment is connected on the hydraulic pump3, one segment is disposed in the inner cavities of the push rod8and the connecting rod2, and another segment is disposed in the pressure measuring segment. The pressure control valve6and the pressure gauge4are also disposed on the high-pressure oil pipe5connected on the hydraulic pump3. The high-pressure oil pipes may be rapidly connected by the oil pipe joints during use. The oil pipe joint is also disposed in the connection casing9to facilitate connection of the high-pressure oil pipes. The pressure control valve6and the pressure gauge4are also disposed on the high-pressure oil pipe5to monitor a hydraulic pressure in the pipe, and an oil inlet valve on the pressure control valve6is closed after hydraulic oil is pumped by the hydraulic pump. Balancing of the pressure in the hydraulic bladder and the pressure in the pipe is realized by using the high-pressure oil pipe5and the pressure control valve6, so that the pressure gauge on the high-pressure oil pipe5can accurately measure the resultant horizontal extrusion force of the borehole at the pressure measuring segment, which more accurately reflects the actual force of the anchor bolt. The pressure gauge4may be a digital pressure gauge with a recording function for recording pressure monitoring data in real time, and the hydraulic pump3may be a high-pressure pump that can measure the horizontal extrusion force in a larger scope. The high-pressure oil pipe5is connected with the oil inlet on the main pipe11by the oil pipe joint, internal threads are disposed at inner sides of the pipe walls at both ends of the main pipe11respectively to be mated with an external thread of the connecting rod2, and external threads are disposed at outer sides of the pipe walls at both ends of the main pipe11respectively to be mated with internal threads of the barrier sheets14. As shown inFIG.2, the connecting rod2is connected with two or more pressure measuring segments1, the number of pressure measuring segments1is selected according to the number and the location of points to be monitored, and the connecting rod2with an appropriate length is selected according to the location of the point to be monitored. This way, the horizontal extrusion force of the point to be monitored can be measured. One communicating high-pressure oil pipe5is disposed for each pressure measuring segment, and the high-pressure oil pipe5is connected with the oil inlet on the main pipe11to ensure that different pressure measuring segments can perform measurement independently. A design length margin of the high-pressure oil pipe5is placed in the connection casing9to ensure that monitoring can be performed at a larger depth of borehole. The outer pillow housing15is divided into four or more parts of same shape, and the combination body of the outer pillow housing15is a cylindrical housing. As shown inFIG.8andFIG.9, the outer pillow housing15is sleeved on the main pipe11in a combination manner when the hydraulic bladder12contracts and expands in four or more parts when the hydraulic bladder12is liquid-filled to expand. After expansion, the outer pillow housing15expands outwardly to closely contact with an inner wall of the borehole under the action of the connection sleeve so as to finally keep balance with the horizontal extrusion force in the borehole. At this time, the hydraulic pressure in the hydraulic bladder12is equal to the horizontal extrusion force, thereby achieving the measurement purpose. The outer pillow housing15and the connection sleeve16may also be fixed together through point bonding or fixed connection. Both ends of the connection sleeve16are closely attached to the main pipe. When the hydraulic bladder12contracts, the connection sleeve16tightly presses both ends of the outer pillow housing15to be in contact with the main pipe so as to protect the hydraulic bladder12. As shown inFIG.10andFIG.11, a through-hole is disposed in the tray7, a protrusion is also disposed at a lower part of the tray7, and the connecting rod2and the push rod8can both pass through the through-hole of the tray. The push rod8may be designed as hollow to protect the safety of the high-pressure oil pipe, and an external thread may also be disposed at the outer side of the push rod to facilitate pushing the monitoring device in the borehole deep into the borehole. During mounting, the tray7is fixed at the opening of the borehole of the roof, and serves to bear the structure in the borehole after the combination of the pressure measuring segment1and the connecting rod2protrudes into the borehole. The connection casing9is connected with the external thread at the protrusion of the tray7, and the push rod8pushes the connecting rod2and the pressure measuring segment1by the connection casing9. The main pipe11and the push rod8may be made of a steel material to ensure a push strength, and the hydraulic bladder12and the connection sleeve16may be made of a flexible rubber material to ensure stretchable elasticity and durability of the structure. A method using the device for monitoring a horizontal extrusion force of roof rock strata, which monitors a change of the horizontal extrusion force along with time. The method includes the following steps. At step a, the connecting rod2with an appropriate length is selected according to the location of the horizontal extrusion force monitoring point and the depth of the borehole, the connecting rod2is connected with the pressure measuring segment1, the high-pressure oil pipes2in the inner cavities of the connecting rod2and the pressure measuring segment1are connected by the oil pipe joint, the tray7is fixed, and the connection casing9is mounted. At step b, the push rod8pushes the connecting rod2and the pressure measuring segment1into the borehole; after the tray7and the roof are fixed, the pressure measuring segment1is mounted, and then the connection casing9and the push rod8are dismounted by loosening the threads. At step c, the exposed high-pressure oil pipes5are easily connected by the oil pipe joints to the hydraulic pump3, the pressure control valve6and the pressure gauge4, where the pressure gauge4and the pressure control valve6are firstly connected, and the hydraulic pump3and the pressure control valve6are then connected. At step d, a switch on the pressure control valve6is turned on to perform pressurization by injecting oil using the hydraulic pump3, and the pressurization is stopped after a reading of the pressure gauge4reaches 5-6 MPa, so that hydraulic oil flows back; air in the high-pressure oil pipe5is emptied as possible by repeating this step 2-5 times. At step e, the pressurization is performed by injecting oil using the hydraulic pump3, and after the reading of the pressure gauge4reaches 5-6 MPa, the pressure control valve6is closed, and then the hydraulic pump3is dismounted. At step f, pressurization is performed for a plurality of pressure measuring segments1respectively through hydraulic oil injection by repeating steps d and e, or hydraulic oil is injected for a plurality of pressure measuring segments1simultaneously by using a plurality of hydraulic pumps3. At step g, after the hydraulic oil is injected into all pressure measuring segments1, the hydraulic pump3is dismounted, and monitoring data of the pressure gauge is monitored and stored; a digital pressure gauge with a data recording function is used to read the monitoring data at a regular interval of time to facilitate monitoring. At step h, the pressure control valve6is opened to discharge the hydraulic oil, and the pressure measuring segment1contracts; the connection casing9and the push rod8are re-connected to take out the connecting rod2and the pressure measuring segment1from the borehole to facilitate reuse. Certainly, the above descriptions are not intended to limit the present disclosure, and the present disclosure is also not limited to the above examples. Changes, modifications, additions or substitutions made by persons skilled in the art within the spirit of the present disclosure shall also belong to the scope of protection of the present disclosure. | 12,167 |
11859494 | DETAILED DESCRIPTION OF THE EMBODIMENTS In order to better understand the technical scheme of the present invention, further description of the present invention will be made below in combination with specific embodiments and drawings of the description. According to one aspect of the present invention, provided is a combined circulating system of a micro gas turbine. As shown inFIG.1, the combined circulating system of the micro gas turbine of the present invention includes: a micro gas turbine100, a heat exchange unit200, a circulating water tank300, a piston engine400and a power generating apparatus500, wherein the micro gas turbine100is provided with a regenerator110; an exhaust port of the regenerator110is connected with an air inlet of the heat exchange unit200to provide a heat source to the heat exchange unit200; the exhaust port of the heat exchange unit200is led to an atmosphere, a water inlet of the heat exchange unit200is connected with a water outlet of the circulating water tank300, a steam outlet of the heat exchange unit200is connected with the piston engine400, high pressure steam enters the piston engine400via the steam outlet to push the piston engine400to act; the piston engine400is connected with the power generating apparatus500to drive the power generating apparatus500to generate electricity; the circulating water tank300is connected with the piston engine400to recover water or a water-vapor mixture converted from acting steam that produces work. Through the structure, tail gas discharged by the regenerator110of the micro gas turbine100is conveyed to the heat exchange unit200, and meanwhile, the circulating water tank300conveys constant temperature water to the heat exchange unit200, in the heat exchange unit200, the constant temperature water absorbs heat in the tail gas and is gasified in the heat exchange unit200to form high pressure steam, the high pressure steam enters the piston engine400to push the piston to act, and the high pressure steam acting becomes constant pressure steam or a water-vapor mixture to enter the circulating water tank300to realize cyclic utilization. Heat in the exhaust gas of the regenerator110is utilized effectively, so that the integral efficiency of the micro gas turbine is improved. The structure of the piston engine of the present invention may be realized by various structures, for example, but not limited to several structures below. Example I In the embodiment, the piston engine400is the single-side entry spring reset type piston engine410. As shown inFIG.2, the piston engine includes an air cylinder block411, a piston412, a spring413, a piston rod414, a slider-crank mechanism415and an output shaft416, wherein the piston412is mounted in the air cylinder block411, one end of the piston rod414is connected with the piston412and the other end of the piston rod stretches out of the air cylinder block411and is connected with the slider-crank mechanism415, the slider-crank mechanism415is connected with the output shaft416, a rodless cavity of the air cylinder block411is provided with a first air inlet411-1and a first exhaust port411-2, the first air inlet411-1is connected with the heat exchange unit200, the first exhaust port411-2is connected with the circulating water tank300, and the output shaft416is connected with a power generating apparatus500; and one side of a rod-containing cavity of the air cylinder block411is provided with the spring413to reset the piston412that produces work. Preferably, switching valves421may be arranged among the first air inlet411-1, the first exhaust port411-2and the air cylinder block411, and on-off of the switching valves421is controlled according to a specific working state of the piston engine, so that action of the piston engine is controlled. Specifically, the switching valves421may be mechanical switching valves or electric switching valves. The electric switching valve is relatively simple in principle to merely meet high frequency on-off. However, it needs to bear relatively high temperature and pressure. The mechanical switching valve needs to be combined with movement of the piston itself, and they are linked, so that frequency limit of process control is omitted, and it will be more complex in structure. In a working state, the high pressure steam enters the rodless cavity of the piston engine via the first air inlet411-1through the heat exchange unit200to push the piston412to move linearly, the piston412converts linear motion of the piston412into a rotating motion of the output shaft416via a crank-link mechanism415, and the output shaft416drives the power generating apparatus500to generate electricity; after acting, the spring413pushes the piston412to reset, and exhaust gas or the steam-vapor mixture in the rodless cavity of the piston engine enters the circulating water tank300via the first exhaust port411-2to be recycled. Example II In the embodiment, the piston engine400is the double-side entry type piston engine420. As shown inFIG.3, based on the embodiment I, the spring413is omitted, and meanwhile, one side of the rod-containing cavity of the air cylinder block411is provided with a second air inlet411-3and a second exhaust port411-4, the second air inlet411-3is connected with the heat exchange unit200, the second exhaust port411-4is connected with the circulating water tank300, and other structures are as same as those in the embodiment I, which is not described and annotated repeatedly. In a working state, the high pressure steam enters the rodless cavity of the piston engine via the first air inlet411-1through the heat exchange unit200to push the piston412to move linearly, the piston412converts linear motion of the piston412into a rotating motion of the output shaft416via a crank-link mechanism415, and the output shaft416drives the power generating apparatus500to generate electricity; after acting, the high pressure steam enters the rod-containing cavity of the piston engine via the second air inlet411-3to push the piston412to move towards the rodless cavity, exhaust gas or the steam-vapor mixture in the rodless cavity of the piston engine enters the circulating water tank300via the first exhaust port411-2to be recycled and then enters a next cycle period, the high pressure steam enters the rodless cavity of the piston engine via the first air inlet411-1to push the piston412to act, and exhaust gas or the steam-vapor mixture in the rod-containing cavity of the piston engine enters the circulating water tank300via the second exhaust port411-4to be recycled. Preferably, switching valves421may be arranged among the first air inlet411-1, the first exhaust port411-2, the second air inlet411-3, the second exhaust port411-4and the air cylinder block411, and on-off of the switching valves421is controlled according to a specific working state of the piston engine, so that reciprocating motion of the piston engine is controlled; the switching valves421may be mechanical switching valves or electric switching valves. Compared with the embodiment I, the spring is omitted in the embodiment. The reciprocating motion of the piston is realized by air intake and exhaust on two sides, so that the control reliability of the piston engine is improved and the structure is simplified. Example III In the embodiment, the piston engine400is the horizontally-opposed double-cylinder control type piston engine430. As shown inFIG.4, the horizontally-opposed double-cylinder control type piston engine430includes a slider-crank mechanism435, and a first air cylinder and a second air cylinder that are oppositely arranged on two sides of the slider-crank mechanism435. The slider-crank mechanism435is of a double slide block structure, including a crank435-1, a first slide block435-2, a first connecting rod435-3, a second slide block435-4, a second connecting rod435-5and an output shaft416; the output shaft416is arranged at a center of the crank435-1in a penetrating manner, one end of the first connecting rod435-3and one end of the second connecting rod435-5are respectively connected to two end surfaces of the crank435-1, connecting points are distributed on two sides of the output shaft416, the other end of the first connecting rod435-3is connected with the first slide block435-2and the other end of the second connecting rod435-5is connected with the second slide block435-4. The first air cylinder includes a first air cylinder block431, a first piston432and a first piston rod434, the first piston432is mounted in the first air cylinder block431, one end of the first piston rod434is connected with the first piston432, and the other end of the first piston rod stretches out of the first air cylinder block431and is connected with the first slide block435-2; one side of a rodless cavity of the first air cylinder block431is provided with a first air inlet411-1and a first exhaust port411-2, the first air inlet411-1is connected with the heat exchange unit200and the first exhaust port411-2is connected with the circulating water tank300. The second air cylinder includes a second air cylinder block437, a second piston438and a second piston rod439, the second piston439is mounted in the second air cylinder block437, one end of the second piston rod439is connected with the second piston438, and the other end of the second piston rod stretches out of the second air cylinder block437and is connected with the second slide block435-4; one side of a rodless cavity of the second air cylinder block437is provided with a second air inlet411-3and a first exhaust port411-4, the second air inlet411-3is connected with the heat exchange unit200and the second exhaust port411-4is connected with the circulating water tank300. In a working state, the high pressure steam enters the rodless cavity of the first cylinder via the first air inlet411-1through the heat exchange unit200to push the piston412to move linearly, a first piston432converts linear motion of the first piston432into a rotating motion of the output shaft416via a crank-link mechanism435, and the output shaft416drives the power generating apparatus500to generate electricity; after acting, the high pressure steam enters the rod-containing cavity of the second air cylinder via the second air inlet411-3to push the second piston438to move towards one side of the rodless cavity, exhaust gas or the steam-vapor mixture in the rodless cavity of the first air cylinder enters the circulating water tank300via the first exhaust port411-2, and after the second air cylinder acts, the high pressure steam then enters the first air cylinder to act continuously, and cycle is repeated to realize continuous work of the output shaft416. It is illustrated that in the graphic structure, when the high pressure steam enters the first air cylinder, the first piston rod434drives the crank435-1of the slider-crank mechanism435to rotate, the crank435-1rotates anti-clockwise, and in the process, the crank435-1simultaneously drives the second piston rod439to move, the second piston rod439drives the second piston438to move towards one side of the crank435-1. When it rotates to a preset angle and the high pressure steam enters the second air cylinder to act, the second piston438drives the second piston rod439to move towards the side away from the crank435-1, and the crank435-1rotates continuously anti-clockwise. At the moment, the exhaust gas or the water-vapor mixture in the rodless cavity of the first air cylinder enters the circulating water tank300via the first exhaust port411-2. In the continuous acting process, when the first air cylinder intakes air to act, the second air cylinder exhausts, and when the second air cylinder intakes air to act, the first air cylinder exhausts, thereby realizing cyclic action. Certainly, the above description is merely a description of a specific working process in a specific implementation mode and does not limit the implementation process and its structure of the present invention. Preferably, switching valves421may be arranged among the first air inlet411-1, the first exhaust port411-2, the second air inlet411-3, the second exhaust port411-4and the air cylinder block, and on-off of the switching valves421is controlled according to a specific working state of the piston engine, so that reciprocating motion of the piston engine is controlled. Specifically, the switching valves421may be mechanical switching valves or electric switching valves. Preferably, the heat exchange unit200may be connected with the first air inlet411-1and the second air inlet411-3through the electromagnetic reversing valve, the first exhaust port411-2and the second exhaust port411-4are connected with the circulating water tank300through the electromagnetic reversing valve, and action of the first air cylinder and the second air cylinder may be controlled by controlling action of the electromagnetic reversing valve, so that it is simpler and more accurate to control the piston engine. In three structures disclosed in embodiments I, II and III, the specific structure of the piston engine400is an air cylinder driven crank-link structure, that is, a straight reciprocating motion of the piston is converted into a rotating motion of the crank and then the power generating apparatus500is driven to generate electricity; besides the structure, a linear motor may be used, that is, the power generating apparatus500is a linear generator, the piston is directly connected to the linear motor, and the linear motion of the piston drives the linear motor directly to generate electricity. Thus, the integral structure may be further simplified. When the usage scenario is limited and it is not suitable for the three structures, the structure of the embodiment below may be used. A specific structure has a principle below: Example IV In the embodiment, the piston engine400is the single-side entry spring reset type piston engine410, including: an air cylinder block411, a piston412, a spring413and a piston rod414, wherein the piston412is mounted in the air cylinder block411, one end of the piston rod414is connected with the piston412and the other end of the piston rod stretches out of the air cylinder block411and is connected with the linear generator; one side of a rodless cavity of the air cylinder block411is provided with a first air inlet411-1and a first exhaust port411-2, the first air inlet411-1is connected with the heat exchange unit200, the first exhaust port411-2is connected with the circulating water tank,300and one side of a rod-containing cavity of the air cylinder block411is provided with the spring413to reset the piston412that produces work. Example V In the embodiment, the piston engine400is the double-side entry type piston engine420, including: an air cylinder block411, a piston412and a piston rod414, wherein the piston412is mounted in the air cylinder block411, one end of the piston rod414is connected with the piston412and the other end of the piston rod stretches out of the air cylinder block411and is connected with the linear generator; one side of the rodless cavity of the air cylinder block411is provided with a first air inlet411-1and a first exhaust port411-2, one side of a rod-containing cavity of the air cylinder block411is provided with a second air inlet411-3and a second exhaust port411-4, the first air inlet411-1and the second air inlet411-3are connected with the heat exchange unit200, and the first exhaust port411-2and the second exhaust port411-4are connected with the circulating water tank300. Example VI In the embodiment, the piston engine400is the horizontally-opposed double-cylinder control type piston engine430, including: a first air cylinder and a second air cylinder, wherein the first air cylinder includes a first air cylinder block431, a first piston432and a first piston rod434, the first piston432is mounted in the first air cylinder block431, one end of the first piston rod434is connected with the first piston432, and the other end of the first piston rod stretches out of the first air cylinder block431and is connected with one end of the linear generator; one side of a rodless cavity of the first air cylinder block is provided with a first air inlet411-1and a first exhaust port411-2, the first air inlet411-1is connected with the heat exchange unit200and the first exhaust port411-2is connected with the circulating water tank300. The second air cylinder includes a second air cylinder block437, a second piston438and a second piston rod439, the second piston439is mounted in the second air cylinder block437, one end of the second piston rod439is connected with the second piston438, and the other end of the second piston rod stretches out of the second air cylinder block437and is connected with the other end of the linear generator; one side of a rodless cavity of the second air cylinder block437is provided with a second air inlet411-3and a first exhaust port411-4, the second air inlet411-3is connected with the heat exchange unit200and the second exhaust port411-4is connected with the circulating water tank300. According to a technology disclosed by the abovementioned embodiments, the structure of the power generating apparatus may be optimally selected according to a working condition and a usage scenario. In the abovementioned six structures, single piston engine is arranged to drive the power generating apparatus to work. Similarly, a plurality of piston engines may be arranged to drive the power generating apparatus to work. That is, there are a plurality of piston engines that correspondingly drive a plurality of cranks to rotate simultaneously. The plurality of cranks are mounted on the same output shaft that is connected with the power generating apparatus. Therefore, the operation reliability of the power generating apparatus may be improved, and meanwhile, the generating efficiency is improved. Optionally, in the structures shown inFIG.4andFIG.7, the rod-containing cavity of the first air cylinder and the rodless cavity of the second air cylinder are connected with a first vacuum pump P1and a second vacuum pump P2, as shown inFIG.8andFIG.9. When the first air cylinder or the second air cylinder act, corresponding vacuum pumps start to work simultaneously to pump corresponding chambers to negative pressure states. As water vapor is used to expand the piston to act, when a backpressure is reduced, that is, the exhausting pressure is reduced by a vacuumizing method, there may be much liquid water in the water vapor that produces work condensed to generate more acting energy, so that the integral generating efficiency is improved. For example, when the pressure in the rod-containing cavity of the first cylinder block is a constant pressure, after steam in the rodless cavity of the first cylinder block acts, the pressure is 0.1 MPa, and after the pressure of the rod-containing cavity of the first air cylinder is pumped to 0.005 MPa via the vacuum pump, in two different backpressure conditions, under an isentropic condition, compared with the constant backpressure, the water vapor will release more energy at 0.005 MPa backpressure, so that the integral acting efficiency is improved by 5-8%. In addition, as circulating water in the present invention is used to absorb waste heat discharged by the regenerator and then the piston is pushed to act, in the piston acting process, it is unnecessary to add lubricating oil and lubricating grease between the piston and the cylinder block and the piston is directly lubricated by water, so that it is unnecessary to arrange extra lubricating structure and lubricating oil supply structure and system, and therefore, the structure of the piston engine is simplified. As a preferred scheme of the present invention, the combined circulating system of the micro gas turbine of the present invention may further recover waste heat of the micro gas turbine. As shown inFIG.10, water in the circulating water tank300may exchange cold and heat with the heating element700first via the heating element700, and the circulating water then enters the heat exchange unit200to exchange heat after the circulating water is raised from constant temperature to a certain temperature. The heating element700generally refers to various elements with the temperatures increased in the working process, including a shell or a rotating shaft of the micro gas turbine100, a shell of the power generating apparatus500and a heating part of a device using the micro gas turbine and the like. For example, the temperature of the gas turbine body shell is about 200° C., the temperature of the power generating apparatus shell is about 80° C., the heat exchange amount is relatively considerable, and specific heat exchange amount is affected by a series of factors such as volume, heat exchange pipe diameter and flow rate, which is no longer described in detail. According to another aspect of the present invention, provided is a transportation means using the combined circulating system of the micro gas turbine. The circulating water may recover heat generated by a driving motor, a battery pack and an apparatus element in the transportation means first, and then enters the heat exchange unit200to exchange to recover heat dissipated by the driving motor, the battery pack and the apparatus element of the transportation tool so as to further improve the heat efficiency of the micro gas turbine. According to another aspect of the present invention, provided is a charging system using the combined circulating system of the micro gas turbine. The circulating water may recover heat generated by the driving motor, the battery pack and the apparatus element in the charging system first, and then enters the heat exchange unit to exchange heat. The charging system may be a charging vehicle, a mobile charging station and the like. An advanced micro gas turbine has a series of advanced technical characteristics such as multiple integrated dilatation, multiple fuels, low rate of fuel consumption, low noise, low emission, low vibration, low maintenance rate, remote control and diagnosis. Besides distributed power generation, the gas turbine may further be used for a standby power station, combined heat and power generation, grid connected power generation, peak load power generation and the like, is the optimum mode that provides clean, reliable, high quality, multipurpose and small distributed power generation and combined heating and power, and is suitable for either a central city or an exurban rural area and even a remote area. The micro gas turbine is simple in structure and quite compact, saves the mounting space, is convenient to mount and carry quickly, and may meet small scale and scattered demand of distributed power supply well. The micro gas turbine is few in moving part, simple and compact in structure, so that the micro gas turbine is good in reliability and low in manufacturing cost and maintenance cost; and the micro gas turbine has the advantages of good environmental adaptability and high power supply quality. The micro gas turbine may be used in distributed power generation. Compared with a central power station, the power station is closer to a user, so that the power station is better in reliability. As far as a terminal user is concerned, compared with other small power generating apparatuses, the micro gas turbine is a better environmental-friendly power generating apparatus, or is about to become one of basic constitutions of public utility in the future, and may operate in parallel to a central power plant. The rotating speed of the 45 KW micro gas turbine with the regenerator is 0-80000 RPM. When the fuel is kerosene, the oil consumption is 200-500 g/kWh, and when the fuel is natural gas, the consumption of natural gas is 0.2-0.5 m3/kWh; the highest circulation power output power may reach 60 KW. The rotating speed of the 45 KW micro gas turbine without the regenerator is 0-80000 RPM. When the fuel is kerosene, the oil consumption is 400-900 g/kWh, and when the fuel is natural gas, the consumption of natural gas is 0.5-1 m3/kWh; the highest circulation power may reach 85 KW. The above description is merely description of preferred embodiments of the present invention and applied technical principles. Those skilled in the art shall understand that the scope of the present invention in the present invention is not limited to the technical scheme specifically combined by the technical characteristics and shall cover other technical schemes formed by combining the technical characteristics or equivalent characteristics thereof without departing the concept of the present invention. For example, the characteristics have similar functions with those disclosed (but not limited to) in the present invention. | 24,923 |
11859495 | DETAILED DESCRIPTION Reference is made to the Figures which show a rotary piston and cylinder device1which comprises a rotor2, a stator4, and a shutter disc3. The stator comprises a formation, such as a housing or casing, which is maintained relative to the rotor, and an internal surface of the stator facing a surface2aof the rotor, together define an annular space or working chamber, shown generally at100. The stator4may comprise two or more parts, which together substantially enclose the rotor and shutter therebetween. Integral with the rotor and extending from the surface2athere is provided a piston5. A slot or opening3aprovided in the shutter disc3is sized and shaped to allow passage of the piston therethrough. Rotation of the shutter disc3is arranged to ensure that the timing of the shutter remains in synchrony with the rotor by a suitable transmission. A transmission assembly, not illustrated, can rotationally connect and synchronise the rotation of the shutter to the rotor. The transmission assembly may include a multiple toothed gears or another transmission type. The shutter disc3is rotationally mounted by way of a shaft portion7. In use of the device, a circumferential surface30of the shutter disc faces the surface2aof the rotor so as to provide a seal therebetween, and so enable the shutter disc to functionally serve as a partition within the annular cylinder space. The geometry of the interior (i.e. facing into and in part defining the chamber) surface2aof the rotor is governed by the part of the circumferential surface30of the rotating shutter disc. The rotor and the stator are configured to provide the annular cylinder space with one or more inlet port/s and one or more outlet port/s for the working fluid, as described in further detail below. The rotor2is located intermediate of distal end portions of the shaft9. Depending on how the device1is used, in terms of its operational application, the shaft may be used to provide rotational input or output. As is evident, since the piston5is of relatively wide dimension, the opening3aof the shutter3must be accordingly proportioned, in order to allow the piston to pass through the opening. It will be appreciated, and is to some extent evident in the drawings, that the boundary of the opening3ahas to be suitably configured/profiled to take account of the relative movement between the piston and the shutter disc. The rotor2is provided with multiple ports10which extend from the surface2athrough to the opposite, or what could be termed outward, surface of the rotor. As will be described further below, this conveniently allows for fluid to be transferred to or from the annular or working chamber of the device. This may be for example compressed fluid. Depending from the stator4, there is provided a formation15, which in this example may be described as a spigot. This feature provides a port, such as an outlet port, for working fluid from the device. The formation15comprises a passageway16with an opening16a, and the opposite end of the passageway16is provided with an opening16b. The ports10of the rotor are arranged to periodically come into register with the opening16bof the stator. It will be appreciated that the view inFIG.1shows a port10in alignment with the port16b. This means that as the rotor2rotates and the port10comes into alignment with the opening16b, and passage16is opened through which fluid can flow into and/or out of the annular chamber100. During assembly or manufacture of the device1, the component parts of the stator, can be rigidly attached together by way of fasteners or by some other way. The chamber100is also defined by an internal (i.e. facing into the chamber) surface4a. Save for the presence of a port14(shown inFIG.2), the surface4ais substantially cylindrical shape. This means, as seen in (axial) cross-section of the chamber the surface4apresents a single, major linear boundary to the chamber. In essence the chamber100(when considered in cross-section of a plane incorporating the axis of rotation of the rotor) is substantially defined by two major surfaces/sides (i.e. the rotor surface2aand the stator surface4a), and what may be termed a two-sided chamber. The rotor surface2ais of substantially concave cross-section, and when considered as a whole can be viewed as presenting the surface of a diabolo. The shaft9being rotatably mounted by bearings20is arranged to rotate about an axis A-A. The port14can provide an inlet for working fluid. If the device1is used as a compressor, a suitable motive or drive source can be attached to the shaft9or to the shaft7of the shutter or to another part of the transmission. The surface2aof the rotor2may be described as being substantially symmetric about the axis of rotation of the rotor. This can be better understood with reference to the plane Y-Y, which extends through a midpoint of the rotor surface2a, and which is perpendicular to the axis of rotation A-A. About this plane, the rotor surface is substantially symmetrical. Put an alternative way, the general orientation/direction of the rotor surface2ais directed substantially perpendicularly to the axis of rotation A-A. InFIG.4a modified version 40 of the device1is shown in which an extended shaft9′ is provided with two bearings20, in essence both being located to one side of the chamber100. The arrangement of a passageway16′ extends along the stator4. Such an arrangement can allow a larger cross-section of passageway16′ than otherwise possible, since all the shaft and bearings are located towards the other side of the chamber. The version 40 of the device also comprises a port10′. Reference is made toFIG.5which shows a further embodiment50in which the rotor surface is orientated at an incline relative to the axis of rotation of the rotor2, as schematically illustrated by the headed broken line. This results in the requirement that the single major surface104aof the stator which defines in part the chamber is of substantially frusto-conical shape. A surface102aof the rotor co-defines the chamber with the surface104aof the stator4. Some of the geometrical characteristics of the outward, inclined orientation of the device50are now discussed.FIG.5serves to illustrate the geometric characteristic of the rotor2of the device50. The rotor surface102amay be described as being orientated an incline relative to the axis of rotation A-A. The inclined, outward, orientation of the rotor surface102acan be described, by extrapolating the surface102a, which in essence extends between the distal end regions of the rotor surface102a, towards the axis of rotation of A-A. That line can then be extended to intercept the axis A-A, at a particular angle of incline x. | 6,752 |
11859496 | DETAILED DESCRIPTION The disclosure now will be described more fully hereinafter through reference to various embodiments. These embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, the disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in the specification, and in the appended claims, the singular forms “a”, “an”, “the”, include plural referents unless the context clearly dictates otherwise. The present disclosure in one embodiment relates to turbine blade designs and methods of use that can reduce or even eliminate turbine blade erosion arising from chemical degradation by air or steam or by particle impingement. The disclosure also provides power production methods and systems that can provide high efficiency operation while reducing or even eliminating turbine blade erosion arising from particulates in a combustion product flow without the requirement of filtration prior to passage through the turbine. The reduction and/or elimination of blade erosion can simplify power production systems and increase possible feedstocks since it allows for the turbines to process combustion product flow with higher total particulate concentration and is thus particularly beneficial in combustion processes using feedstocks, such as coal, that include a relatively high concentration of particulates in the combustion product. The terms “particulates” and “particles” (including such terms in the singular form) as used in relation to components of the combustion product stream specifically encompass solid and liquid materials present in the combustion product stream in a relatively small unit size typically understood to be characteristic of particles, specifically in relation to the overall volume of the combustion product stream. In some embodiments, particles or particulates may comprise any material in the combustion product stream that is in a non-gaseous state. Liquid particulates specifically may encompass materials that are liquid at the temperature of the combustion product stream but that are solid at a temperature that is less than the temperature of the combustion product stream, such as at least 10° C., at least 15° C., at least 20° C., at least 30° C., at least 50° C., or at least 100° C. less than the temperature of the combustion product stream. Such liquid particulates may have a freezing point that is at least ambient temperature, at least about 40° C., at least about 50° C., at least about 60° C., at least about 80° C., at least about 100° C., or at least about 200° C. In specific embodiments, the liquid particles may have a freezing point falling within any combination of the above-listed temperatures (e.g., within the range that is at least 10° C. less than the temperature of the combustion product stream and at least ambient temperature). In particular embodiments, the present disclosure realizes that particle impact damage on turbine blades is related to blade velocity. In particular, a damage rate arising from particle impact can change as approximately the cube of blade velocity relative to particle velocity. In this regard, the standard alternating current frequency employed in the United States is 60 Hz. Further, power production systems in the United States typically drive synchronous alternating current generators that operate at either 1,800 rpm (30×60 Hz) or 3,600 rpm (60×60 Hz), although it should be understood that the turbines may rotate within other rpm ranges. In this regard, other countries may employ differing standard alternative current frequencies. For example, the United Kingdom operates at a frequency of 50 Hz. Further, generator systems may employ permanent magnet direct current generators driven at any speed such that the direct current is converted to alternating current having a desired frequency. Accordingly, it should be understood that the frequencies discussed herein are provided for example purposes only. However, known gas turbines used in power production systems and methods including synchronous alternating current generators typically operate at blade speeds of 600 mph (268 m/s) or greater. At blade speeds typical in existing steam and gas turbines, the presence of even very small particulates in a combustion product flow can cause blade erosion. The present disclosure, however, has recognized the ability to overcome blade erosion through alterations in blade structure and operation that allows for decreased blade velocities. In specific embodiments, blade velocity according to the present disclosure may be from about 20 m/s to about 340 m/s at the blade tip. More specifically, the blade velocity may be below 200 m/s, below 100 m/s, or from about 50 m/s to about 75 m/s. In one embodiment, the disclosure can provide for turbine operation at a blade velocity that is about 3 times lower than typical (i.e., 200 mph (89 m/s)), which may result in a decrease in blade erosion rate of 27 fold or more. In one embodiment, a blade velocity of 150 mph (67 m/s)—i.e., a four-fold decrease from typical blade velocities—can provide approximately a 64 fold decrease in blade damage rate. The ability to operate the turbine in a power production system at a lower velocity can arise from a variety of factors that can be embodied singularly or in multiple combinations. For example, the turbine blades can be designed with dimensions that can allow for the blade velocity to be slowed to a speed where particle impingement no longer causes erosion of the turbine blades. More specifically, the operating blade speed can be reduced below the critical velocity at which erosion occurs. In this regard, the blade speed at any given point on a blade is provided by the following formula: v=(rpm/60)*2*π*r(Formula 1) where:v=blade speed (m/s),rpm=rotations of the blade per minute,π=pi, andr=distance (m) between a center of the rotor and a point on the blade at which the blade velocity is to be determined (e.g., radius). Note further that the blade speed at the tip of a blade is provided by the following formula: vt=(rpm/60)*2*π*(a+b) (Formula 2) where:vt=blade speed (m/s) at the tip of the blade,rpm=rotations of the blade per minute,π=pi,a=radius (m) of the rotor at the blade, andb=blade height (m). Thus, the maximum blade speed for each blade may be reduced by decreasing the distance to which the blades extend from the center of the rotor. As discussed below, use of turbines having blades extending to relatively smaller radii may be enabled by employing a supercritical fluid having relatively high fluid density and high pressure at a moderate flow velocity in the turbine of the present disclosure. Further, employing a high density working fluid in the turbine may provide for significantly reduced turbine blade temperature by improving the ability of transpiration to cool the blades. Blade height (i.e., the distance from a root at the outer surface of the turbine shaft (e.g. rotor) to the blade tip) preferably is less than about 0.275 m. In specific embodiments, average blade height can be about 0.05 m to about 0.25 m, about 0.075 m to about 0.225 m, about 0.1 m to about 0.2 m, or about 0.125 m to about 0.175 m. In specific embodiments, actual blade heights could vary from the turbine inlet to the turbine outlet. For example, blade height at the inlet could be lower than the average and increase toward the outlet such that blade height at the outlet is higher than the average. Average blade width can be about 0.025 m to about 0.125 m, about 0.04 m to about 0.11 m, about 0.05 m to about 0.1 m, or about 0.06 m to about 0.09 m. In other embodiments, blade height and width can be further dimensions that allow for operation at a velocity as described herein. The inventive turbines and methods of operation also can be characterized by overall turbine dimensions. For example, a turbine according to the disclosure can have an overall length of less than about 11 m, less than about 10 m, or less than about 9 m. In further embodiments, overall turbine length can be about 6 m to about 10 m, about 6.5 m to about 9.5 m, about 7 m to about 9 m, or about 7.5 m to about 8.5 m. A turbine according to the disclosure can have an average diameter of less than about 3.5 m, less than about 3 m, or less than about 2.5 m. In further embodiments, average turbine diameter can be about 0.25 m to about 3 m, about 0.5 m to about 2 m, or about 0.5 m to about 1.5 m. The ratio of turbine length to turbine average diameter (i.e., diameter of the turbine blades) can be greater than about 3.5, greater than about 4, greater than about 4.5, or greater than about 5. In specific embodiments, the ratio of turbine length to turbine average diameter can be about 3.5 to about 7.5, about 4 to about 7, about 4.5 to about 6.5, or about 5 to about 6. The above ratios specifically can relate to the total length of the turbine. In some embodiments, total length may refer to the length of the casing from inlet to outlet. In certain embodiments, total length may refer to the distance within the casing from the turbine blade immediately adjacent the inlet to the turbine blade immediately adjacent the outlet. The inventive turbines and methods of operation likewise can be characterized by average blade radius (center of the rotor to tip of the turbine blade). Preferably, the turbines operate with an average blade radius of less than about 1.2 m, less than about 1.1 m, less than about 1 m, less than about 0.9 m, less than about 0.8 m, less than about 0.7 m, or less than about 0.6 m. Turbine blade radius specifically can be about 0.25 m to about 1 m, about 0.275 m to about 0.8 m, about 0.3 m to about 0.7 m, about 0.325 m to about 0.6 m, about 0.35 m to about 0.5 m, or about 0.375 m to about 0.475 m. In certain embodiments, a turbine useful according to the disclosure can have a total number of turbine blades that is significantly less than present in typical gas turbine systems. Specifically, the inventive turbines may have less than about 3,000 blades, less than about 2,500 blades, or less than about 2,000 blades. In further embodiments, the number of blades in a turbine can be about 500 to about 2,500, about 750 to about 2,250, about 1,000 to about 2,000, or about 1,250 to about 1,750. In some embodiments, the turbines according to the disclosure particularly can provide high efficiency power production with reduced blade velocity through operation at significantly increased inlet pressure, and/or significantly increased outlet pressure, and/or significantly increased pressure drop from inlet to outlet in relation to typical gas turbine power production systems. In specific embodiments, the turbine can be operated at an inlet pressure of at least about 25 bars (2.5 MPa), at least about 50 bars (5 MPa), at least about 100 bars (10 MPa), at least about 150 bars (15 MPa), at least about 200 bars (20 MPa), or at least about 250 bars (25 MPa). In further embodiments, inlet pressure can be about 50 bars (5 MPa) to about 500 bars (50 MPa), about 100 bars (10 MPa) to about 450 bars (45 MPa), about 150 bars (15 MPa) to about 400 bars (40 MPa), about 200 bars (20 MPa) to about 400 bars (40 MPa), or about 250 bars (25 MPa) to about 350 bars (35 MPa). In further embodiments, the turbine can be operated with an outlet pressure of at least about 5 bars (0.5 MPa), at least about 10 bars (1 MPa), at least about 15 bars (1.5 MPa), at least about 20 bars (2 MPa), or at least about 25 bars (2.5 MPa). The outlet pressure particularly may be about 10 bars (1 MPa) to about 50 bars (5 MPa), about 15 bars (1.5 MPa) to about 45 bars (4.5 MPa), about 20 bars (2 MPa) to about 40 bars (4 MPa), or about 25 bars (2.5 MPa) to about 35 bars (3.5 MPa). In other embodiments, the ratio of turbine inlet pressure to turbine outlet pressure can be at least about 6, at least about 7, at least about 8, at least about 9, or at least about 10. In specific embodiments, the ratio of turbine inlet pressure to turbine outlet pressure can be about 6 to about 15, about 7 to about 14, about 8 to about 12, or about 9 to about 11. In yet other embodiments, the turbines according to the disclosure can be operated in a power production system at a significantly increased flow density in relation to operation of turbines in typical power production systems. For example, the inventive turbines can be operated at a flow density of at least about 20 kg/m3, at least about 50 kg/m3, at least about 100 kg/m3, at least about 150 kg/m3, at least about 200 kg/m3, or at least about 300 kg/m3, at least about 400 kg/m3, at least about 500 kg/m3, or at least about 600 kg/m3. In contrast to the turbines in accordance with the present disclosure, existing gas turbine compressors may operate with outlet pressures from about 1 Bar (0.1 MPa) to about 15 Bar (1.5 MPa), with gas densities in the compressor section ranging from 1 kg/m3to about 15 kg/m3(assuming adiabatic compression heating). Erosion and other problems may not be severe in the compressor due to the relatively low temperatures therein. However, in the hot section, the gas temperature may vary from a peak of roughly 1727° C. to about 527° C. The density of the gas in the hot section may vary from a high of about 5 kg/m3to a low of about 0.5 kg/m3. Thus, the conditions inside existing turbines may vary considerably from those within the turbines in accordance with the present disclosure. The use of higher pressures at lower flow rates and higher temperatures may increase the torque on the turbine blades. Accordingly, the turbine may include features configured to reduce the torque applied to the blades. In particular, the turbine may include a larger number of blades, discs, and/or stages than conventional turbines, which distributes the torque therebetween to reduce the torque applied to the individual blades. Further, the blades may define an angle of attack configured to exert less force and torque on the blades. In particular, the blades may define a decreased angle with respect to the flow through the turbine, which induces less drag and increases the lift to drag ratio. Accordingly, these features may reduce the torque exerted on each of the blades so that they may be formed from relatively less strong and relatively less expensive materials. In some embodiments, blade erosion also may be controlled, reduced, or eliminated by combining any of the above-described characteristics with one or more methods of blade cooling. Any method of turbine blade cooling could be combined with the present disclosure, including transpiration blade cooling, as more fully described below. In this regard, transpiration cooling may be employed to cool any of the various components of the turbine, combustor, and related apparatuses disclosed herein. With particular regard to the turbine, the case, stators (e.g., stator blades), seals, blades (e.g., turbine blades), rotor, and various other internal components may be transpiration cooled through, for example, employing the porous materials disclosed herein. In this regard, the stators may comprise the porous sintered material and the porous sintered material may be configured to direct the transpiration fluid to an exterior surface of the stators. Additionally, one or more of the components of the turbine assembly may be configured to direct transpiration fluid to the seals. The seals may comprise the porous sintered material in some embodiments. Example embodiments of seals and stators that may be transpiration cooled in accordance with embodiments of the disclosure are described in U.S. Pat. App. Pub. 2009/0142187, which is incorporated herein by reference in its entirety. However, various other embodiments of components of turbines, combustors, and related apparatuses may also be transpiration cooled in accordance with the present disclosure. Further, the transpiration cooling techniques disclosed herein may provide improved cooling relative to existing transpiration cooling techniques. Current blade cooling is typically conducted with bleed air from the compressor of the turbine. This air has a limited heat capacity due to its relatively low density (e.g., 0.5-5 kg/m3) set by the relatively low operating pressure of the turbine hot section in existing turbines, as described above. This limits the heat transfer rates. In contrast, as discussed below, the present disclosure provides for transpiration cooling through use of CO2, which may provide improved heat transfer. The heat transfer rates for existing embodiments of turbines are also limited by the relatively large stress placed on the turbine blades due to the long length of the blades resulting in high centrifugal forces during rotation thereof. The cooling passages in existing turbines thus must be kept relatively small and they must not define more than a relatively small fraction of the blade overall cross-sectional area in order to limit the reduction in longitudinal strength of the blades caused by the cooling passages. The inventive turbines are particularly useful in systems and methods for power production in that the turbines not only provide for reduced blade erosion but also can significantly reduce total turbine cost. In specific embodiments, total turbine cost in relation to turbines used in typical power production systems can be reduced by at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, or at least 75% without any significant loss in electrical power output (i.e., loss of less than 5%, less than 4%, less than 3%, less than 2%, less than 1%, or less than 0.8%). Reductions in cost may occur by avoiding the need for superalloys and/or other expensive materials in the blades due, for example, to a reduction in the centrifugal forces applied thereto. Further, reductions in power output may be minimized despite reduced rotating speeds by employing high inlet temperatures in the turbine as well as high operating pressures relative to existing embodiments of turbines. In specific embodiments, the present disclosure can comprise systems and methods for power production that can incorporate the present turbine blade designs and modes of operation. For example, the inventive systems and methods allow for power production through use of a high efficiency fuel combustor (such as a transpiration cooled combustor), optionally with an associated circulating fluid (such as a CO2circulating fluid). Specifically, the use of a high pressure circulating fluid (or working fluid) that has a high CO2recycle ratio provides the ability to direct a portion of the CO2circulating fluid to the turbine blades for transpiration cooling. The combination of transpiration cooling with the blade designs and modes of operation of the present disclosure particularly can be useful since erosion can be a function of turbine blade temperature and blade material composition. The combination of turbine blade design and operation with blade operation temperature can provide for a wide range of possible blade operation velocities and blade operation temperatures wherein blade erosion can be controlled, reduced, or eliminated. At lower blade temperatures, erosion is lower, and the blade velocity at which erosion starts can be higher. The ability to choose operation conditions is beneficial in that it can allow for the use of metal alloys that can resist erosion at higher blade velocities but otherwise would not be available for use at higher operating temperatures. In this regard, at lower temperatures, high strength steels are relatively immune to impact damages. As an example, rolled homogenous armor used on military vehicles is not damaged by solid steel bullets traveling at up to speeds of 400 mph (179 m/s). In other embodiments, however, as more fully described below, transpiration may effect blade protection by preventing solidification of combustion product stream components (e.g., liquid ash). In such embodiments, transpiration cooling may be defined as cooling the blades (and/or other components) to a temperature below the temperature of the combustion product stream. More particularly, such cooling may be configured to have a lower limit that is greater than the temperature at which a component of the combustion product stream (e.g., liquid ash) will freeze (or solidify) and thus become deposited upon the turbine blades. For example, ash softening may begin at 590° C., and melting may occur at 870° C. Without transpiration cooling, the turbine would need to operate well below 590° C. to avoid ash buildup on the blades, which is too low for efficient operation. With transpiration protection, the turbine can operate above 870° C., where the ash is liquid, but the liquid droplets do not touch or stick to the surface because of the transpiration vapor layer covering substantially all surfaces that are internal to the turbine and thus subject to contact with components of a stream flowing through the turbine (e.g., the internal surface of the turbine housing, the external surfaces of the turbine blades within the turbine, etc.). Thus, transpiration protection may reduce or eliminate not only degradation due to mechanical erosion by particle impingement, but also chemical degradation by keeping the blades cooler, and by replacing air or air/steam as the coolant with CO2as the coolant in the form of a transpiration fluid. In some embodiments, it can be useful for the turbines to be operated at blade velocities that are relative to the velocity of the combustion product flow. In such embodiments, it can be particularly beneficial for flow velocity to be significantly less than flow velocities in typical combustion processes. For example, flow velocity according to the disclosure can be less than about 400 mph (179 m/s), less than about 350 mph (156 m/s), less than about 300 mph (134 m/s), less than about 250 mph (112 m/s), less than about 200 mph (89 m/s), less than about 150 mph (67 m/s), or less than about 100 mph (45 m/s). The ratio of blade tip velocity to flow velocity preferably is greater than 1, greater than 1.5, greater than 2, greater than 2.5, or greater than 3. Specifically, the ratio of blade tip velocity to flow velocity can be about 1 to about 5, about 1.5 to about 4.75, about 1.75 to about 4.5, about 2 to about 4.25, or about 2.5 to about 4. As a result of erosion, turbines may experience degradation in performance over time (e.g., through reduced efficiency and/or power output). For example, a conventional turbine may experience operational degradation of 10% power loss over a two to three year period. An overhaul to repair the turbine may cost approximately 50% of the purchase cost of the turbine. Accordingly, over a 20 year lifetime, existing turbines may be overhauled a total of eight times, which may cost a total of 4 times the initial purchase price of the turbine. This degradation may be due to erosion caused by residual dust particles that get past an air filtration system positioned between the combustor and the turbine. Increasing the particulate removal effectiveness of the filters may not be a viable option because this may restrict air flow and reduce efficiency of the turbine. Thus, the turbines of the present disclosure may provide significant cost savings by minimizing or eliminating the need for overhauls by minimizing or eliminating damage from erosion. In this regard, the rate of dissipation of impact energy associated with collision between the particles and blades is approximately proportional to the cube of the relative velocity therebetween. In this regard, erosion of turbine blades tends to be approximately proportional to the rate of impact energy dissipation (“Impact Power”), as illustrated below: IP=kV3/X(Formula 3) where:IP=impact power,k=a variable factor based on the particle material, the blade material, the ambient temperature, and the impact angle,v=relative velocity between the turbine blades and particles, andX=characteristic length of the impact interaction. By reducing the speed of the blades and providing transpiration protection, impacts may be minimized or reduced below a threshold at which erosion occurs and chemical damage may also be reduced or eliminated. Accordingly, expenses associated with overhauls due to erosion may be reduced or eliminated, and thus embodiments of the turbines provided herein may provide significant cost savings. Further, as noted above, by eliminating the need for use of expensive superalloys, the turbines in accordance with the present disclosure may be relatively less expensive than existing turbines. In various known embodiments of power plants, efficiency is critically dependent on turbine inlet temperatures. For example, extensive work has been done at great cost to achieve turbine technology allowing for inlet temperatures as high as about 1,350° C. The higher the turbine inlet temperature, the higher the plant efficiency, but also the more expensive the turbine is, and potentially, the shorter its lifetime. Because of the relatively high temperature of the combustion product stream, it can be beneficial for the turbine to be formed of materials capable of withstanding such temperatures. It also may be useful for the turbine to comprise a material that provides good chemical resistance to the type of secondary materials that may be present in the combustion product stream. In certain embodiments, the present disclosure can particularly provide for the use of a cooling fluid with the turbine components. As more fully described below, for example, the inventive systems and methods allow for power production through use of a high efficiency fuel combustor (e.g., a transpiration cooled combustor) and an associated circulating fluid (such as a CO2circulating fluid). Specifically, a portion of the circulating fluid can be directed to the turbine components, particularly the turbine blades, to be used in turbine cooling, such as through transpiration cooling. For example, in some embodiments, a portion of a CO2circulating fluid can be withdrawn from the cycle (e.g., from a portion of the cycle where the circulating fluid is under conditions useful for a transpiration cooling fluid) and directed to a turbine for cooling of the components, particularly the turbine blades. The blade cooling fluid can be discharged from holes (or perforations) in the turbine blade and be input directly into the turbine flow. Thus, rather than using air as a transpiration cooling fluid (which is limited in its cooling ability as described above, and hampered by safety concerns), the methods and systems of the disclosure provide for the use of very large quantities of high pressure CO2, supercritical CO2, and even liquid CO2as a turbine blade cooling medium. This is highly useful because it increases the cooling capacity available for the turbine blades by large ratios in relation to known blade cooling methods. The disclosure also is particularly useful because the CO2circulating fluid can be present in the system in very large quantities, which allows for a very large quantity of cooling fluid to be moved through the turbine blades. This high volume and/or high mass flow of CO2cooling fluid through the turbine blades not only protects the turbine blades from the extreme heat that is useful for high efficiency power production methods, but it also assists in protecting the turbine blades from the corrosive and erosive effects of the high temperature gases and unfiltered particulate material flowing through the turbine by transpiration of the CO2cooling fluid out through the entire surface of the blade. In one embodiment transpiration cooling may provide for operational blade temperatures from about 200° C. to about 700° C. despite the significantly higher turbine inlet temperatures described above (e.g., 1350° C.), which may thus allow for use of turbine blades comprising relatively less expensive materials than those which are presently employed and/or higher turbine inlet temperatures may be employed, which may lead to greater efficiency. The foregoing transpiration cooled turbine components can be used in any power production method and system wherein high pressure CO2(or other fluid which is less corrosive than air or steam, such as N2) can be made available as a high recycle ratio circulating fluid. In specific embodiments, the use of a CO2circulating fluid as a turbine blade cooling medium allows for the turbine blades to be fabricated from much lower cost materials than known turbine blades used in high efficiency power production methods because use of the CO2cooling medium prevents the blades in the present disclosure from being heated to the extreme temperatures of the surrounding combustion product flow and reduces the corrosive and erosive effects of the combustion product flow. For example, according to the present disclosure, turbine blades could be fabricated from a wide variety of high strength steels, or even relatively low cost steels. Likewise, the blades could be fabricated from carbon composites or even low temperature materials, such as aluminum. Any material recognized as useful in the art for gas turbine components, even for turbines used in low temperature conditions and/or low erosive or low corrosive conditions, could be used for fabricating turbine components according to the present disclosure. Transpiration cooling of turbine blades with a portion of a CO2circulating fluid according to the present disclosure further is useful because it can facilitate the safe passage of combustion gasses containing ash (or other particulate matter and/or incombustibles) through the turbine without the need for an intervening filtration step and component. This can greatly simplify the design of power production facilities and increase the types of materials that may be used as the fuel source for combustion. The use of a CO2circulating fluid in transpiration cooling of turbine components according to the present disclosure also is advantageous in relation to the thermodynamics of the power production cycle. Because of the vastly improved cooling ability of the CO2circulating fluid in relation to known transpiration media for turbine blades, it is possible to operate the combustor at increased temperatures without the limitation of the heat tolerance of the turbine. Thus, combustors capable of operation at extremely high temperatures (e.g., transpiration cooled combustors) can be operated according to the present disclosure at near maximum operating temperatures since the combustion product flow can be passed through the CO2cooled turbine without damage to the turbine components. This increases the potential thermodynamic efficiency of the power production cycle to approaching 100%. Any combination of turbine blade design, overall turbine design, and transpiration cooling of the turbine blades can be used in any power production method where turbine blade life is desirably extended, such as methods and systems where combustion results in formation of particulates. In some embodiments, the methods and systems particularly can be those wherein a circulating fluid can be used. For example, high pressure CO2can be made available as a high recycle ratio circulating fluid. For example, a turbine as described herein may be used in a method and system wherein a CO2circulating fluid is provided in a combustor along with an appropriate fuel, any necessary oxidant, and any associated materials that may be useful for efficient combustion. Such systems and methods can comprise a combustor that operates at very high temperatures (e.g., in the range of about 1,600° C. to about 3,300° C., or even greater), and the presence of the circulating fluid can function to moderate the temperature of a fluid stream exiting the combustor so that the fluid stream can be utilized in energy transfer for power production. Specifically, a combustion product stream can be expanded across at least one turbine to generate power. The expanded gas stream can be cooled to remove various components from the stream, such as water, and heat withdrawn from the expanded gas stream can be used to heat the CO2circulating fluid. The purified circulating fluid stream can then be pressurized and heated for recycle through the combustor. Exemplary power production systems and methods that may incorporate the turbine blade designs of the present disclosure (with or without associated blade transpiration cooling) are described in U.S. Pat. App. Pub. 2011/0179799, which is incorporated herein by reference in its entirety. The incorporation of a turbine according to the disclosure in a combustion power cycle is particularly useful in relation to combustion of fuels that result in a particulate component. Various types of coal, for example, can be combusted in a power production cycle to produce a combustion stream having a content of ash and/or other particulates. Beneficially, when a turbine according to the disclosure is incorporated into the combustion cycle, the full combustion product stream (i.e., including the full content of particulates) can be introduced into the turbine without the need of a preliminary filtering step. This enables the use of higher turbine inlet temperature which in turn increases combustion efficiency in relation to processes requiring filtration of the combustion product prior to passage through the turbine. This is possible according to the disclosure since the inventive turbines can be subjected to particle impingement without significant erosion. Particulate materials then can be filtered from the stream exiting the turbine. One embodiment of a combustion cycle provided according to the present disclosure is illustrated in the flow diagram ofFIG.1. In the illustrated embodiment, an air separation unit100is provided to intake ambient air10and output an enriched oxygen stream120. The oxygen stream120may comprise oxygen having a molar purity of at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 85%, at least about 90%, or at least about 95%. The oxygen stream120may be supplied, for example, by any air separation system/technique known in the art, such as, for example, a cryogenic air separation process, or a high temperature ion transport membrane oxygen separation process (from air), could be implemented. In specific embodiments, an enriched oxygen stream may be produced by the operation of a cryogenic air separation process in which the oxygen is pressurized in the process by pumping liquid oxygen that is efficiently heated to ambient temperature conserving refrigeration. Such a cryogenic pumped oxygen plant can have two air compressors, both of which can be operated adiabatically with no inter-stage cooling. In specific embodiments, it may be useful to include components useful for recovering heat produced by the air separation unit and transferring the heat to a component of the presently described system where heat input may be desirable. The cycle illustrated inFIG.1can be useful for combustion of any fuel source that includes particulate matter (e.g., ash) as a component of the combustion product. Non-limiting examples of fuels that are useful according to the disclosure include various grades and types of coal, wood, oil, tar from tar sands, bitumen, biomass, algae, graded combustible solid waste refuse, asphalt, and used tires. In particular, any solid fuel material may be used in the disclosure, and such fuels particularly may be ground, shredded, or otherwise processed to reduce particles sizes, as appropriate. A fluidization or slurrying medium can be added, as necessary, to achieve a suitable form and to meet flow requirements for high pressure pumping. For example, referring toFIG.1, the solid fuel15can be passed through a mill apparatus200to provide a powdered fuel. In other embodiments, the solid fuel15could be provided in a particularized condition to forego the need for on-site milling. In specific embodiments, the solid fuel15may have an average particle size of about 10 μm to about 500 μm, about 25 μm to about 400 μm, or about 50 μm to about 200 μm. In other embodiments, the solid fuel15may be described in that greater than 50%, 60%, 70%, 80%, 90%, 95%, or 99% of the solid fuel particles have an average size of less than about 500 μm, 400 μm, 300 μm, 200 μm, or 100 μm. The solid fuel15can be suitably processed to allow for injection into a combustion apparatus at sufficient rates and at pressures above the pressure within the combustion chamber. To provide such characteristic, the solid fuel15may be in liquid, slurry, gel, or paste form with appropriate fluidity and viscosity at ambient temperatures or at elevated temperatures. For example, the solid fuel15may be provided at a temperature of about 30° C. to about 500° C., about 40° C. to about 450° C., about 50° C. to about 425° C., or about 75° C. to about 400° C. When the solid fuel15is in a ground, shredded, or otherwise processed condition so that particle size is appropriately reduced, a fluidization or slurrying medium can be added, as necessary, to achieve a suitable form and to meet flow requirements for high pressure pumping. As illustrated in the embodiment ofFIG.1, the particulate solid fuel220produced from the solid fuel15by the mill apparatus200can be mixed with a fluidizing substance to provide the coal in the form of a slurry. In particular, the particulate solid fuel220is combined in a mixer250with a CO2side draw562from a recycled CO2circulating fluid stream561. The CO2side draw562may be provided in a supercritical, high density state. In specific embodiments, the CO2used to form the slurry can have a density of about 450 kg/m3to about 1,100 kg/m3. More particularly, the CO2side draw562may cooperate with the particulate solid fuel220to form a slurry255having, for example, from about 10 weight % to about 75 weight % or from about 25 weight % to about 55 weight % of the particulate coal. Moreover, the CO2from the side draw562used to form the slurry255may be at a temperature of less than about 0° C., less than about −10° C., less than about −20° C., or less than about −30° C. In further embodiments, the CO2from the side draw562used to form the slurry may be at a temperature of about 0° C. to about −60° C., about −10° C. to about −50° C., or about −18° C. to about −40° C. Although the slurrying step is described in terms of using CO2as a slurry medium, it is understood that other slurrying mediums could be used. The slurry255can be transferred from the mixer250via a pump270to a combustion apparatus300. In specific embodiments, the combustion apparatus300can be a high efficiency combustor capable of providing substantially complete combustion of a fuel at a relatively high combustion temperature. High temperature combustion can be particularly useful to provide for substantially complete combustion of all combustible components of the fuel and thus maximize efficiency. In various embodiments, high temperature combustion can mean combustion at a temperature of at least about 1,000° C., at least about 1,200° C., at least about 1,500° C., at least about 2,000° C., or at least about 3,000° C. In further embodiments, high temperature combustion can mean combustion at a temperature of about 1,000° C. to about 5,000° C. or, about 1,200° C. to about 3,000° C. In certain embodiments, the combustion apparatus300may be a transpiration cooled combustor. One example of a transpiration cooled combustor that may be used in the disclosure is described in U.S. Pat. App. Pub. No. 2010/0300063 and U.S. Pat. App. Pub. No. 2011/0083435, the disclosures of which are incorporated herein by reference in their entirety. In some embodiments, a transpiration cooled combustor useful according to the disclosure may include one or more heat exchange zones, one or more cooling fluids, and one or more transpiration fluids. The use of a transpiration cooled combustor according to the present disclosure is particularly advantageous over the known art around fuel combustion for power production. For example, the use of transpiration cooling can be useful to prevent corrosion, fouling, and erosion in the combustor. This further allows the combustor to work in a sufficiently high temperature range to afford complete or at least substantially complete combustion of the fuel that is used. These, and further advantages, are further described herein. In one particular aspect, a transpiration cooled combustor useful according to the disclosure can include a combustion chamber at least partially defined by a transpiration member, wherein the transpiration member is at least partially surrounded by a pressure containment member. The combustion chamber can have an inlet portion and an opposing outlet portion. The inlet portion of the combustion chamber can be configured to receive the carbon containing fuel to be combusted within the combustion chamber at a combustion temperature to form a combustion product. The combustion chamber can be further configured to direct the combustion product toward the outlet portion. The transpiration member can be configured to direct a transpiration substance therethrough toward the combustion chamber for buffering interaction between the combustion product and the transpiration member. In addition, the transpiration substance may be introduced into the combustion chamber to achieve a desired outlet temperature of the combustion product. In particular embodiments, the transpiration substance can at least partially comprise the circulating fluid. The walls of the combustion chamber may be lined with a layer of porous material through which the transpiration substance, such as CO2and/or H2O, is directed and flows. The flow of the transpiration substance through this porous transpiration layer, and optionally through additional provisions, can be configured to achieve a desired total exit fluid stream outlet temperature from the combustion apparatus300. In some embodiments, as further described herein, such temperature can be in the range of about 500° C. to about 2,000° C. This flow may also serve to cool the transpiration member to a temperature below the maximum allowable operational temperature of the material forming the transpiration member. The transpiration substance may also serve to prevent impingement of any liquid or solid ash materials or other contaminants in the fuel which might corrode, foul, or otherwise damage the walls. In such instances, it may be desirable to use a material for the transpiration member with a reasonable thermal conductivity so that incident radiant heat can be conducted radially outwards through the porous transpiration member and then be intercepted by convective heat transfer from the surfaces of the porous layer structure to the fluid passing radially inwards through the transpiration layer. Such a configuration may allow the subsequent part of the stream directed through the transpiration member to be heated to a temperature in a desirable range, such as about 500° C. to about 1,000° C. or from about 200° C. to about 700° C., while simultaneously maintaining the temperature of the porous transpiration member within the design range of the material used therefor. Suitable materials for the porous transpiration member may include, for example, porous ceramics, refractory metal fiber mats, hole-drilled cylindrical sections, and/or sintered metal layers or sintered metal powders. A second function of the transpiration member may be to ensure a substantially even radially inward flow of transpiration fluid, as well as longitudinally along the combustor, to achieve good mixing between the transpiration fluid stream and the combustion product while promoting an even axial flow of along the length of the combustion chamber. A third function of the transpiration member can be to achieve a velocity of diluent fluid radially inward so as to provide a buffer for or otherwise intercept solid and/or liquid particles of ash or other contaminants within the combustion products from impacting the surface of the transpiration layer and causing blockage, erosion, corrosion, or other damage. Such a factor may only be of importance, for example, when combusting a fuel, such as coal, having a residual inert non-combustible residue. The inner wall of the combustor pressure vessel surrounding the transpiration member may also be insulated to isolate the high temperature transpiration fluid stream within the combustor. In certain embodiments, a mixing arrangement (not illustrated) may be provided to combine the materials to be introduced into the combustion apparatus300prior to such introduction. Specifically, any combination of two or all three of the fuel, O2, and circulating fluid (e.g., CO2circulating fluid) may be combined in the optional mixing arrangement prior to introduction into the combustion apparatus300. The fuel15introduced to the combustion apparatus300(as the slurry stream255) along with the O2120and a recycled circulating fluid503is combusted to provide a combustion product stream320. In specific embodiments, the combustion apparatus300is a transpiration cooled combustor, such as described above. Combustion temperature can vary depending upon the specific process parameters—e.g., the type of fuel used, the molar ratio of circulating fluid to carbon in the fuel as introduced into the combustor, and/or the molar ratio of CO2to O2introduced into the combustor. In specific embodiments, the combustion temperature is a temperature as described above in relation to the description of the transpiration cooled combustor. In particularly preferred embodiments, combustion temperatures in excess of about 1,000° C., as described herein, may be advantageous. It also can be useful to control combustion temperature such that the combustion product stream leaving the combustor has a desired temperature. For example, it can be useful for the combustion product stream exiting the combustor to have a temperature of at least about 700° C., at least about 900° C., at least about 1,200° C., or at least about 1,600° C. In some embodiments, the combustion product stream may have a temperature of about 700° C. to about 1,600° C. or about 1,000° C. to about 1,500° C. Specifically, the pressure of the combustion product stream320can be related to the pressure of the circulating fluid that is introduced into the combustion apparatus300. In specific embodiments the pressure of the combustion product stream320can be at least about 90% of the pressure of the circulating fluid introduced into the combustion apparatus300. The chemical makeup of the combustion product stream320exiting the combustion apparatus300can vary depending upon the type of fuel used. Importantly, the combustion product stream will comprise the major component of the circulating fluid (e.g., CO2) that will be recycled and reintroduced into the combustion apparatus300or further cycles. In further embodiments, the combustion product stream320may comprise one or more of water vapor, SO2, SO3, HCI, NO, NO2, Hg, excess O2, N2, Ar, incombustibles and/or other particulate matter, and possibly other contaminants that may be present in the fuel that is combusted. These materials present in the combustion product stream may persist in the CO2circulating fluid stream unless removed, such as by processes described herein. Advantageously, according to the present disclosure, the combustion product stream320can be directed to a turbine400without the necessity of first filtering out any particulate material in the combustion product stream320. In the turbine400, the combustion product stream320is expanded to generate power (e.g., via a generator400ato produce electricity). The turbine400can have an inlet for receiving the combustion product stream320and an outlet for release of a turbine discharge stream410. Although a single turbine400is shown inFIG.1, it is understood that more than one turbine may be used, the multiple turbines being connected in series or optionally separated by one or more further components, such as a further combustion component, a compressing component, a separator component, or the like. The turbine400specifically can be a turbine having a blade design and/or overall design as otherwise described herein. Further, the turbine may incorporate transpiration cooling or other cooling technology, as described herein. In particular, the turbine design can be one with such low blade velocity and ash particle impingement velocity such as to enable the turbine to endure impingement without significant erosion. Transpiration cooling of the turbine further can protect against particle erosion by creating a continuous flow barrier layer of the transpiration fluid between the blade surface and the particulate material passing through the turbine. Returning toFIG.1, the exemplary system and cycle further comprises a filter5downstream from the turbine400. The turbine discharge stream410can be passed through the filter5to remove the particulate materials therefrom. The placement of the filter5downstream of the turbine400, instead of upstream of the turbine, is an advantageous characteristic of the disclosure since the combustion product stream320can be expanded across the turbine at the higher temperature and pressure when immediately exiting the combustor apparatus300and thus power production may be maximized. The lower pressure and cooler turbine discharge stream410can then be filtered in the filter5to remove the particulate materials therefrom as particulate stream7. The filtered turbine discharge stream420thus is provided substantially free from particulate material for further processing in the combustion cycle. In specific embodiments, the filter5preferably can comprise a configuration that is effective for removing substantially all of the particulate material present in the combustion product stream320. The filter5may comprise a cyclone filter and/or a candle filter in some embodiments, and filtration may occur from about 300° C. to about 775° C. in some embodiments. In particular embodiments, removal of substantially all of the particulates can encompass removal of at least 95%, at least 96%, at least 97%, at least 98%, at least 99%, at least 99.5%, or at least 99.8% by volume of the particulates present in the combustion product stream. Such particulate removal efficiency of the filter can be related to particle size. For example, the noted percentage of particles removed can relate to the ability of the filter to retain particles having a diameter of at least about 0.1 μm, at least about 0.5 μm, at least about 1 μm, at least about 5 μm, at least about 10 μm, at least about 25 μm, at least about 50 μm, at least about 100 μm, or at least about 500 μm. In one embodiment the particles produced by combustion may be in the range from about 0.1 μm to about 100 μm, and the filter may be configured to remove substantially all particles above about 1 μm, above about 5 μm, above about 10 μm, above about 15 μm, or above about 20 μm and reduce the total particulate levels to less than about 10 mg/m3, less than about 5 mg/m3, less than about 1 mg/m3, or less than about 0.5 mg/m3. In particular embodiments (i.e., wherein CO2is used as a circulating fluid), the filtered turbine discharge stream420can be passed through a heat exchanger unit500(which may be a series of heat exchangers) to form an unprocessed recycle stream501. This unprocessed recycle stream501can be passed through a cold water heat exchanger520to form stream521, which is passed to a separator540for removal of secondary components (e.g., H2O, SO2, SO4, NO2, NO3, and Hg) as a stream542. In specific embodiments, the separator540can comprise a reactor that provides a contactor with sufficient residence times such that the impurities can react with water to form materials (e.g., acids) that are easily removed. A purified circulating fluid stream541from the separator540can be passed through a compressor550to form stream551, which can be further cooled with a cold water heat exchanger560to provide a supercritical, high density CO2circulating fluid561. In certain embodiments, the purified CO2circulating fluid541can be compressed to a pressure of at least about 7.5 MPa or at least about 8 MPa. A portion of stream561can be withdrawn as stream562for use as the fluidizing medium in the mixer250to form the slurry stream255. The supercritical, high density CO2circulating fluid stream561otherwise is further pressurized in compressor570to form the pressurized, supercritical, high density CO2circulating fluid stream571. A portion of the CO2in stream571may be withdrawn as stream572to a CO2pipeline or other means of sequestration. The remaining portion of the CO2can proceed as pressurized, supercritical, high density CO2circulating fluid stream573, which can be passed back through the heat exchanger500(or series of heat exchangers) to heat the stream. In specific embodiments, the CO2circulating fluid can be provided at a density of at least about 200 kg/m3, at least about 300 kg/m3, at least about 500 kg/m3, at least about 750 kg/m3, or at least about 1,000 kg/m3after discharge from the cold water heat exchanger560(and prior to passage through the heat exchanger unit500for heating). In further embodiments, the density may be about 150 kg/m3to about 1,100 kg/m3. Passage of the stream551through the cold water heat exchanger560can cool the CO2circulating fluid to a temperature of less than about 60° C., less than about 50° C., or less than about 30° C. The CO2circulating fluid in stream561entering the second compressor570can be provided at a pressure of at least about 12 MPa. In some embodiments, the stream can be pressurized to a pressure of about 15 MPa to about 50 MPa. Any type of compressor capable of working under the noted temperatures and capable of achieving the described pressures can be used, such as a high pressure multi-stage pump. The heated, pressurized, supercritical, high density CO2circulating fluid can exit the heat exchanger500as first stream503to be provided as the recycled circulating fluid. In some embodiments, the heated, pressurized, supercritical, high density CO2circulating fluid can exit the heat exchanger500as a second recycled circulating fluid stream504to be provided as a transpiration fluid for the turbine blades. Preferably, the second recycled circulating fluid stream504can be controllable such that the total mass or volume of circulating fluid in the stream can be increased or decreased as demand requires increasing or decreasing the protection provided by the transpiration fluid. Specifically, a system according to the disclosure can include flow control means such that the second recycled circulating fluid stream504can be completely stopped when desired. Note that in some embodiments the recycled circulating fluid (e.g., CO2) provided to the turbine400may bypass the heat exchanger500prior to being provided to the turbine. In this regard, the recycled CO2may be compressed by the compressor570and then a portion of circulating fluid stream571may bypass the heat exchanger500and enter the turbine400. Thereby CO2(or other recycled circulating fluid) may be introduced into the turbine400without being warmed by the heat exchanger500. Accordingly, the CO2(or other recycled circulating fluid) may be introduced into the turbine at a temperature that is less than the temperature of fluid warmed by the heat exchanger. In this regard, the CO2(or other recycled circulating fluid) may be introduced into the turbine at a temperature of less than about 300° C., less than about 200° C., less than about 100° C., less than about 55° C., or less than about 25° C. and thus, the CO2(or other recycled circulating fluid) may be employed to cool the turbine400. In order to compensate for adding relatively cooler circulating fluid to the turbine400, O2may travel through the heat exchanger500to warm the O2and then the O2may be combined with the recycled circulating fluid503directed to the combustor300to compensate for the loss in efficiency that may otherwise occur. In certain embodiments, circulating fluid leaving the cold end of the heat exchanger (or the final heat exchanger in the series when two or more heat exchangers are used) can have a temperature of less than about 200° C., less than about 100° C., less than about 75° C., or less than about 40° C. In certain embodiments, it may thus be useful for the heat exchanger receiving the turbine discharge stream to be formed from high performance materials designed to withstand extreme conditions. For example, the heat exchanger may comprise an INCONEL® alloy or similar material. Preferably, the heat exchanger comprises a material capable of withstanding a consistent working temperature of at least about 700° C., at least about 900° C., or at least about 1,200° C. It also may be useful for one or more of the heat exchangers to comprise a material that provides good chemical resistance to the type of secondary materials that may be present in the combustion product stream. INCONEL® alloys are available from Special Metals Corporation, and some embodiments can include austenitic nickel-chromium-based alloys. Suitable heat exchangers can include those available under the tradename HEATRIC® (available from Meggitt USA, Houston, TX). As noted above, in addition to water, the CO2circulating fluid may contain other secondary components, such as fuel-derived, combustion-derived, and oxygen-derived impurities. These secondary components of the CO2circulating fluid (often recognized as impurities or contaminants) can all be removed from the cooled CO2circulating fluid using appropriate methods (e.g., methods defined in U.S. Patent Application Publication No. 2008/0226515 and European Patent Application Nos. EP1952874 and EP1953486, which are incorporated herein by reference in their entirety). For example, SO2and SO3can be converted 100% to sulfuric acid, while >95% of the NO and NO2can be converted to nitric acid. Any excess O2present in the CO2circulating fluid can be separated as an enriched stream for optional recycle to the combustor. Any inert gases present (e.g., N2and Ar) can be vented at low pressure to the atmosphere. As described above, a power production cycle incorporating a turbine that is configured according to the disclosure can operate at a high efficiency in part because the combustion product stream (e.g., arising from combustion of a solid fuel, such as coal) can be inputted directly into the turbine without the need for first filtering out particulate material present in the combustion product stream. Particularly, the inventive turbine configurations eliminate or greatly reduce blade erosion arising from impingement of the non-combusted material. Even though the disclosure provides such valuable protection of the turbine materials, there still may be occasion for turbine impairment arising from interaction of the turbine components with the particulate components of the combustion product stream. For example, liquid ash sticking and freezing (or solidifying) onto the turbine blades can cause slagging, loss of efficiency, and/or loss of rotor balance. Accordingly, in certain embodiments, the present disclosure provides for incorporation of specific components into a combustion cycle for alleviating and/or at least partially removing buildup or chemical deposits from turbine components, particularly turbine blades. Although ash buildup is exemplified herein, it is understood that the cleaning provided by embodiments of the present disclosure would be expected to be effective in at least partially removing or completely removing any type of deposit on the turbine components arising from materials present in the combustion product stream, particularly particulate materials. Thus, various types of ash, ash derived material, and carbon may be removed by the cleaning provided herein. Buildup of chemical deposits on turbine components, such as turbine blades, may be prevented by employing transpiration protection techniques. For example, as seen inFIG.1, hot recycled working fluid (e.g., CO2) can be withdrawn from the hot end of the heat exchanger500as stream504and delivered to the turbine400. For example, the hot recycled working fluid can be delivered to the turbine rotor and then through the turbine blades to provide transpiration protection of the turbine blades. In such embodiments, the turbine blades can be perforated as necessary so that a hot recycled working fluid exits the blades along substantially the entire surface of the blades, or at least the leading surface of the blades that is in the direct path of the combustion product stream entering the turbine. In specific embodiments, the greatest flow of transpiration fluid out of the blades would be at the leading edges of the blades. The transpiration fluid may be provided at various temperatures. In some embodiments, the transpiration fluid for the turbine may be at a temperature that is within about 10%, within about 8%, within about 5%, or within about 2% of the temperature of the combustion product stream entering the turbine. In such embodiments, the temperature of the transpiration fluid for the turbine may be characterized as being substantially similar to the temperature of the combustion product stream entering the turbine. In other embodiments, the transpiration fluid directed to the turbine for transpiration protection may be 15% to about 90% less than, about 15% to about 60% less than, about 15% to about 50% less than, or about 20% to about 40% less than the temperature of the combustion product stream entering the turbine. In such embodiments, the temperature of the transpiration fluid for the turbine may be characterized as being substantially less than the temperature of the combustion product stream entering the turbine. In some embodiments, the use of the transpiration fluid with the turbine blades can perform multiple functions. For example, the transpiration fluid can be effective for protecting the turbine blades as it can essentially prevent particulate materials in the combustion product stream from actually contacting the blade surface. Rather, the protective barrier formed by the transpiration fluid can deflect or otherwise redirect the particulate materials around the turbine blades. The hot recycled working fluid also can function to heat the blades, particularly the blade surfaces on the outlet side of the turbine. This additional heating can prevent the blade surfaces, on the outlet side and/or the inlet side, from cooling to a temperature wherein liquid ash (or other materials that are liquid at the temperature of the combustion product stream and have a freezing (or solidification) point that is less than the temperature of the combustion product stream but greater than ambient temperature) will solidify (i.e., the freezing temperature of the material). This prevents the liquid particles that actually contact the surface of the turbine blade from freezing (or solidifying) and thus depositing on the blade surfaces. Transpiration protection can eliminate particle freezing (or solidifying) in some embodiments. In this regard, all ash may remain molten above approximately 870° C.-980° C. in some embodiments. In other embodiments, particle freezing can be reduced in relation to identical cycles and systems that do not incorporate transpiration protection. To the extent particle freezing is reduced but not eliminated, periodic cleaning of the turbine components may be necessary. In specific embodiments, cleaning of turbine components, such as turbine blades, may be effected through incorporation of cleaning components into a combustion cycle or system. The cycle shown inFIG.2illustrates a system wherein turbine blade cleaning materials can be directed through the turbine to effect cleaning of the turbine blades. Beneficially, the cleaning materials may be directed through the turbine in parallel with the combustion product stream. Thus, cleaning can be effected without interrupting the power production combustion cycle. In some embodiments, it may be desirable to alter one or more of the cycle parameters discussed herein to facilitate the cleaning process (e.g., to alter the temperature of the combustion product stream, to increase the ratio of recycle fluid to fuel, or the like). In embodiments wherein the turbine blade is being transpiration protected, it may be desirable to cease the transpiration fluid flow to facilitate contact of the cleaning material with the turbine blades. However, combustion and power generation may continue during the cleaning process. Referring toFIG.2, a combustion cycle can proceed substantially as described above in relation toFIG.1. In the present embodiments, however, a third recycled circulating fluid stream506can exit the heat exchanger500and pass through a cleaning material junction600wherein the cleaning material is combined with the third recycled circulating fluid stream506to form the cleaning material stream610. The cleaning material junction600can comprise any structure, unit, or device suitable for combining the third recycled circulating fluid stream506with the cleaning material wherein the cleaning material is provided in a continuous flow or is provided batchwise. Preferably, the cleaning material junction is configured such that the cleaning material is combined with and flows with the third recycled circulating fluid stream506. As also described above in relation to the second recycled circulating fluid stream504, the third recycled circulating fluid stream506can be controlled such that the flow rate can be zero or can be any rate necessary to effectively transfer the cleaning material to the turbine. The cleaning material can be any material effective to contact the surface of the turbine blades and physically or chemically remove solid deposits therefrom. Preferably, the cleaning material comprises a material that is effective to remove the deposits with minimal to no erosion of the blade surfaces themselves. Solid cleaning materials may include carbon particles, alumina particles, or other hard particles configured to not melt at the flow temperatures. Erosion of ash but not the blades may occur at the low impact velocities because the ash may define a lower fracture strength than the blade. Liquid cleaning materials may include potassium compounds such as potassium oxide, carbonate, or hydroxide. The potassium compounds may act as a flux to lower the melting point of the ash so it may melt off the blades. Gaseous cleaning materials may include oxygen which may oxidize deposits such as carbon. Solid or liquid cleaning materials combined with the third recycled circulating fluid stream506at the cleaning material junction600may define less than about 0.5%, less than about 0.1%, or less than about 0.01% of the total mass flow rate of the cleaning material stream610and from about 0.001% to about 0.1%, from about 0.1% to about 1%, or from about 0.0001% to about 0.01% of the total mass flow rate of the cleaning material stream. Gaseous cleaning materials combined with the third recycled circulating fluid stream506at the cleaning material junction600may define less than about 5%, less than about 2%, or less than about 1% of the total mass flow rate of the cleaning material stream610and from about 0.1% to about 2%, from about 0.01% to about 1%, or from about 0.01% to about 5% of the total mass flow rate of the cleaning material stream. In one embodiment the cleaning cycle may be initiated whenever the power output by the generator400adrops from about 2% to about 5%, from about 5% to about 10%, or from about 1% to about 2%. For example, the cleaning operation may be conducted from about once per week to about once every three years. The cleaning cycle may last from about five minutes to about one hour in some embodiments. The cleaning material stream610may flow directly into the turbine400. In such embodiments, the cleaning material stream may mix with the combustion product stream320in a common inlet to the turbine400, or the cleaning material stream610and combustion product stream320may have individual inlets into the turbine such that the streams mix at a point interior to the turbine400. In the illustrated embodiment, the cleaning material stream610is first mixed with the combustion product stream320in a flow combiner switch650. Thus, in a cleaning cycle, the combined combustion product and cleaning material stream326exits the flow combiner switch650and enters the turbine400. In some embodiments, continuous cleaning may be used wherein some minimal flow of the third recycled circulating fluid stream506can be maintained such that an amount of cleaning material is continuously introduced into the turbine. The flow of the third recycled circulating fluid stream506could be adjusted up or down periodically to increase or reduce the cleaning capacity of the cycle. In other embodiments, the third recycled circulating fluid stream506can be closed so that no cleaning material passes from the cleaning material junction600into the flow combiner switch650. In this mode of operation, the combustion product stream320may bypass the flow combiner switch650and pass directly into the turbine, as illustrated inFIG.1. Alternately, the combustion product stream320may continue to flow through the combiner switch650but, in the absence of an incoming cleaning material stream610, the stream exiting the combiner switch650would be essentially the combustion product stream320and not the combined combustion product and cleaning material stream326. In embodiments wherein the cleaning cycle is active, the deposits or residue removed from the turbine blades can be removed from the cycle via the filter5in the manner described in relation toFIG.1. Likewise, when solid cleaning materials are used, the solid cleaning materials can be removed from the cycle via the filter5. In some embodiments, the filter5may be a multi-unit filter wherein a first filter media or unit is used in the normal course of the combustion cycle, and a second filter media or unit can be used during the cleaning cycle to collect the cleaning material and the removed blade deposits without unnecessarily fouling the filter used in the normal combustion cycle. The inventive system could incorporate the appropriate devices to facilitate such switching between filters. Example Embodiments The present disclosure will now be described with specific reference to the following examples, which are not intended to be limiting of the disclosure and are rather provided to show exemplary embodiments. FIG.3illustrates an example embodiment of a combustor1000that may be employed in accordance with the systems and methods disclosed herein. The combustor1000may define a combustion chamber1002into which fuel and O2are directed through a fuel inlet1004and an O2inlet1006. Accordingly, the fuel may be combusted to form a combustion product stream1008. The combustor1000may comprise a casing comprising an outer casing1010and an inner casing1012. The inner casing1012may comprise a transpiration material such as a porous sintered material (e.g., a porous sintered metal material) that is configured to receive a transpiration fluid1014and transpire the fluid therethrough to define a transpiration layer1016configured to reduce the heat incident on the casing. The transpiration fluid1014may be received in some embodiments through an inlet1026, although the transpiration fluid may be received from a turbine attached to the combustor in some embodiments, as described below. Accordingly, the combustor1000may be configured to withstand the heat produced in the combustion chamber1002without employing expensive heat resistant materials such as superalloys and/or the combustor may operate at increased combustion temperatures. As described above, the combustion product stream produced by a combustor may be employed to drive a turbine. In this regard,FIG.4illustrates an example embodiment of a turbine2000. In one embodiment the turbine2000may include an inlet conduit2002configured to couple to an outlet of a combustor (e.g., combustor1000) and direct a combustion product stream (e.g., combustion product stream1008) to an inlet of a casing2004of the turbine. The turbine2000may comprise a rotor2006to which a plurality of blades2008are attached. The rotor2006may comprise an annular flow diverter2010configured to divert the combustion product stream around the rotor. Accordingly, the combustion product stream1008may be expanded while traveling through the turbine2000, thereby causing the blades2008to rotate the rotor2006and a power shaft2011(which may be integral with the rotor, or coupled thereto) before a turbine discharge stream2012is discharged through one or more outlets2014. Thus, the turbine2000may drive a generator, or other device. As further illustrated inFIG.4, the inlet conduit2002may comprise an inner casing2016and an outer casing2018. Further, the casing2004of the turbine2000may comprise an inner casing2020and an outer casing2022. A transpiration fluid2024may be directed from an inlet2026between the inner casings2016,2020and the outer casings2018,2022of the inlet conduit2002and the turbine2000. The inner casings2016,2020may comprise a transpiration material such as a porous sintered material (e.g., a porous sintered metal material) that is configured to receive the transpiration fluid2024and transpire the fluid therethrough. Thereby a transpiration layer2028may be defined between the combustion product stream1008and the inner surface of the inlet conduit2002and a transpiration layer2030may be defined between the blades2008and an inner surface of the inner casing2020and the inner casings may be cooled or otherwise protected by the transpiration fluid2024. In some embodiments the transpiration fluid provided to the turbine may also be provided to the combustor for transpiration cooling. In this regard, for example, the inlet conduit may mate to the combustor such that the transpiration fluid is provided thereto in some embodiments. However, transpiration fluid provided to the combustor may additionally or alternatively be provided from a separate inlet1026in some embodiments. Further, transpiration fluid2024may also be introduced into the turbine2000through a second inlet2032, which may be defined in the power shaft2011in some embodiments. Accordingly, the transpiration fluid2024may travel through the power shaft2011into the rotor2006. The rotor2006and/or the blades2008may comprise a transpiration material such as a porous sintered material (e.g., a porous sintered metal material) that is configured to receive the transpiration fluid2024and transpire the fluid therethrough to outer surfaces thereof. Accordingly, the rotor2006and/or the blades2008may be cooled or otherwise protected from the combustion product stream1008and particulates therein by the transpiration fluid2024. FIGS.5and6illustrate an alternate embodiment of a turbine2000′. As illustrated, a plurality of combustors1000′ may be configured to drive the turbine2000′. In particular, the combustors2000′ may be radially disposed with respect to a major axis defined by the rotor2006′, as illustrated inFIG.6. As shown inFIG.5, the turbine2000′ may be substantially similar to the embodiment of the turbine2000illustrated inFIG.4, except the combustors1000′ may supply combustion product streams1008′ around the circumference of the rotor2006′. Accordingly, an annular flow diverter may not be needed to divert the combustion product streams1008′ around the rotor2006′. Each of the combustors1000′ may be substantially similar to the combustor1000described above except for the placement of the combustors around the rotor2006′. FIG.7illustrates a lateral sectional view through an embodiment of a turbine blade2008A that may be employed in the turbines disclosed herein. The turbine blade2008A may comprise an outer layer3002and a core3004. The core3004may define a relatively strong metal, or other material configured as a reinforcement member. A strong metal, as used herein, refers to a metal with a strength greater than about 10,000 PSI, greater than about 20,000 PSI or greater than about 30,000 PSI at appropriate elevated temperatures and that is chemically resistant at appropriate temperatures. Examples include stainless steel alloys and high nickel alloys such as Inconel, etc. Thus, the present disclosure allows lower cost alloys such as stainless steel (e.g., 316 stainless steel) or other alloys with lower nickel and cobalt contents to be used instead of the typical superalloys which have relatively very high nickel and cobalt contents, and are thus very expensive. In this regard, a polycrystalline 316 stainless steel can be as much as twenty times less expensive per pound than a polycrystalline superalloy, and two-thousand times cheaper per pound than single crystal superalloy blades. Further, the core3004may define one or more channels3006. The channels3006may be configured to receive transpiration fluid and direct the transpiration fluid into the outer layer3002. The outer layer3002may define a portion, or the entirety, of an exterior surface3008of the blade2008A in some embodiments. Further, the outer layer3002may comprise a porous material such as a porous sintered metal material. Accordingly, the channels3006in the core3004may be configured to receive transpiration fluid and direct the transpiration fluid into the outer layer3002. Thus, the transpiration fluid may flow through the outer layer3002of the turbine blade2008A and provide a transpiration layer around the exterior surface3008of the turbine blade which may protect the turbine blade from heat and/or impacts with particulates. In this regard, it should be understood that a turbine blade and/or other components of the systems disclosed herein may be transpiration protected, meaning a transpiration fluid is directed to at least a portion of a surface thereof, regardless of whether the transpiration cools the component. For example, a component may be transpiration protected by a transpiration fluid that protects a surface of the component from impact with particulates or other matter regardless of the temperature of the transpiration fluid. Conversely, a component may additionally or alternatively be transpiration protected by a transpiration fluid that cools the component or acts as a barrier that reduces heating of the component. As described above, transpiration fluid may additionally or alternatively be employed in other components associated with the systems and assemblies described herein. In this regard,FIG.8illustrates a sectional view through a portion of an inlet conduit2002A configured to deliver a combustion product stream from a combustor to a turbine. The inlet conduit2002A may comprise an inner layer4002and an outer layer4004. The outer layer4004may comprise a shell, which may comprise a strong metal as described above, configured to provide strength to the inlet conduit2002A. Further, the outer layer4004may define one or more channels4006. The channels4006may be configured to receive transpiration fluid and direct the transpiration fluid into the inner layer4002. The inner layer4002may define a portion, or the entirety, of an inner surface4008of the inlet conduit2002A in some embodiments. Further, the inner layer4002may comprise a porous material such as a porous sintered metal material. Accordingly, the channels4006in the outer layer4004may be configured to receive transpiration fluid and direct the transpiration fluid into the inner layer4002. Thus, the transpiration fluid may flow through the inner layer4002of the inlet conduit2002A and provide a transpiration layer at the inner surface4008of the inlet conduit which may protect the inlet conduit from heat and/or impacts with particulates. As illustrated inFIG.9, in one embodiment of an inlet conduit2002B, an insulation layer4010and a second outer layer4012may additionally be provided. The insulation layer4010and the second outer layer4012may surround the inner layer4002and the outer layer4004in some embodiments. The insulation layer4010may insulate the inlet conduit2002B so as to retain more heat therein, which may increase the efficiency of the system in which it is employed. Further, the second outer layer4012may provide additional strength to the inlet conduit2002B. However, the various material layers and features described above may additionally or alternatively be employed in other components of the systems and assemblies described herein, such as in a combustor. FIG.10illustrates a longitudinal sectional view through a turbine blade2008B in accordance with an alternate embodiment. The turbine blade2008B may comprise one or more reinforcement members such as one or more rods5014. The rods5014may comprise a metal material, or other material configured to provide strength to the turbine blade2008B. The turbine blade2008B may further define one or more channels5006. The channels5006may be configured to receive transpiration fluid and direct the transpiration fluid into the material defining the turbine blade2008B. In this regard, the turbine blade2008B may comprise a porous material such as a porous sintered metal material. Accordingly, the channels5006in the turbine blade2008B may be configured to receive transpiration fluid and direct the transpiration fluid through the turbine blade to provide a transpiration layer at an outer surface5008of the turbine blade which may protect the turbine blade from heat and/or impacts with particulates. In some embodiments the turbine blade2008B may be configured to define a flow of transpiration fluid at a leading edge5016of the turbine blade that is greater than a flow of the transpiration fluid at a trailing edge5018of the turbine blade. This may provide the leading edge with greater protection, which may be desirable since the leading edge may otherwise be more prone to impacts with particles than the remainder of the turbine blade. In this regard, one or more channels5006in the turbine blade2008B may define a transpiration fluid inlet area at the leading edge5016(see, e.g., channel5006A) that is greater than a transpiration fluid inlet area of one or more channels at the trailing edge5018(see, e.g., channel5006B). Alternatively, a greater number of channels may be defined at the leading edge than at the trailing edge. FIGS.11-13illustrate an alternate embodiment of a turbine blade2008C. As illustrated, the turbine blade2008C may define an integral structure comprising one or more internal ribs6020. The internal ribs6020may function as a reinforcement member configured to provide strength to the turbine blade2008C. The internal ribs6020may be integrally formed with an outer layer6002and/or a base member6022of the turbine blade2008C. The turbine blade2008C may include one or more channels6006that may be separated by the internal ribs6020. The channels6006may be configured to receive transpiration fluid (e.g., from a rotor to which the base member6022attaches) and direct the transpiration fluid through the outer layer6002. In this regard, the turbine blade2008C may comprise a porous material such as a porous sintered metal material. Accordingly, the channels6006in the turbine blade2008C may be configured to receive transpiration fluid and direct the transpiration fluid through the outer layer6002of the turbine blade to provide a transpiration layer at an outer surface6008of the turbine blade which may protect the turbine blade from heat and/or impacts with particulates. As further illustrated, the channels6006in the turbine blade2008C may define a transpiration fluid inlet area at the leading edge6016(see, e.g., channel6006A) that is greater than a transpiration fluid inlet area of one or more channels at the trailing edge6018(see, e.g., channel6006B). Accordingly, in some embodiments the turbine blade2008C may be configured to define a flow of transpiration fluid at a leading edge6016of the turbine blade that is greater than a flow of the transpiration fluid at a trailing edge6018of the turbine blade. FIG.14illustrates a lateral cross-sectional view through an additional embodiment of a turbine blade2008D. As illustrated, the turbine blade2008D may comprise an outer layer7002that defines a wall thickness at the trailing edge7018that is greater than a wall thickness at the leading edge7016. In this regard, the turbine blade2008D may comprise a porous material such as a porous sintered metal material. Accordingly, transpiration fluid may be directed through the turbine blade2008D such that it travels through the outer layer7002to provide a transpiration layer at an outer surface7008of the turbine blade which may protect the turbine blade from heat and/or impacts with particulates. Since the wall thickness of the outer layer7002is greater at the trailing edge7018than at the leading edge7016, the turbine blade2008D may define a flow of transpiration fluid at the leading edge that is greater than a flow of the transpiration fluid at the trailing edge. Further, the turbine blades in accordance with the various embodiments disclosed herein may define a porosity that varies between the root and tip of a turbine blade (see, e.g., the root6026and tip6028of the turbine blade2008C illustrated inFIG.13). In this regard, in some embodiments the turbine blades disclosed herein may be configured to define a flow of the transpiration fluid at the tip of the turbine blade that is greater than a flow of the transpiration fluid at the root of the turbine blade. This may provide the turbine blades with additional protection which may be desirable since the tip of the turbine blade moves at a greater velocity than any other point on the turbine blade. For example,FIG.15Aschematically illustrates a longitudinal sectional view through a turbine blade2008E. As illustrated, the turbine blade2008E defines a porosity that differs between the root8026and the tip8028. In particular, the turbine blade2008E is more porous at the tip8028than the root8026such that relatively more transpiration fluid may flow out of the tip of the turbine blade than the root of the turbine blade. In this regard, the turbine blade2008E may comprise a porous material such as a porous sintered metal material configured to transpire a transpiration fluid therethrough, as discussed above. As illustrated, in some embodiments the porous material may define a plurality of layers8030A-D, wherein the porosity of the layers increases from root to tip. The layers8030A-D may be defined by different materials or by the same material which has been sintered to various extents, and hence the porosity thereof varies. In some embodiments the layers may be laminated together, although the layers may be attached in various other manners. In another embodiment, as illustrated inFIG.15B, the turbine blade2008E′ defines a porosity that differs between the root8026′ and the tip8028′, as described above with respect toFIG.15B. However, as illustrated, in some embodiments the porous material may define a porosity gradient, wherein, for example, the porosity of the material increases from the8026′ to the tip8028′. In this regard, the porosity of the material may change at various locations without there being distinct layers defining different porosities in some embodiments. Various other configurations for the turbine blades may be employed. For example, in some embodiments the turbine blades may be configured to define a flow of transpiration fluid at the leading edge that is substantially equal to, or less than, the flow of transpiration fluid at the trailing edge of the turbine blades. Further, in some embodiments the turbine blades may be configured to define a flow of transpiration fluid at the tip that is substantially equal to, or less than, the flow of transpiration fluid at the root of the turbine blade. Further, variations in porosity between the leading edge and trailing edge may also be used to control the flow of transpiration fluid out of the blades in a similar manner as described with respect to controlling transpiration flow between the root and tip. Thus, for example, the porosity of the material defining the turbine blade (or other component) may increase between the root and tip, decrease between the root and tip, be relatively higher or lower in the center relative to outer portions of the blade, increase or decrease from the leading edge to the trailing edge, etc. The porosity gradient or porosity layers may increase or decrease from about 10% porosity to about 90% porosity, about 25% porosity to about 75% porosity, or about 1% porosity to about 25% porosity. Accordingly, transpiration fluid may be configured to cool and/or otherwise protect various components of the systems and assemblies disclosed herein. In this regard,FIG.16illustrates a calculated trajectory900for a 100 μm ash particle902relative to an outer surface904of a turbine blade906. The ash particle trajectory900is modeled based on the ash particle902initially traveling at 75 m/s toward the turbine blade906with a flow of CO2transpiration fluid908transpiring from the outer surface904of the turbine blade at 2 m/s. Circulating fluid in the turbine may be at 300 Bar (30 MPa) and 700° C. As illustrated, the transpiration fluid908prevents the ash particle902from coming into contact with the turbine blade906. In particular, the ash particle902is calculated to come about 0.2 mm from the outer surface904of the turbine blade. Accordingly, erosion of the turbine blade906may be avoided. Similarly,FIG.17illustrates one example according to the present disclosure of a calculated particle trajectory1000for a 50 μm ash particle1002relative to an inner surface1004of a combustor1006. The ash particle trajectory1000is modeled based on the ash particle1002initially traveling at a velocity of 50 m/sec perpendicular to the inner surface1004of the combustor1006with an axial flow velocity of the combustion gas of about three meters per second, a combustion gas composition of over about 90% CO2, a combustion gas temperature of about 1,500° C., a pressure of about 300 Bar (30 MPa), and a radial transpiration flow rate of the transpiration fluid1008of about one meter per second in the radial direction, (e.g., perpendicular to the axial combustion gas flow). As illustrated, the transpiration fluid1008prevents the ash particle1002from coming into contact with the inner surface1004of the combustor1006. The ash particle1002is calculated to come only about 0.2 mm from the inner surface1004of the combustor1006. Accordingly, erosion of the inner surface1004of the combustor1006may be avoided. Table 1 below provides various parameters for operation of a conventional power plant natural gas turbine design. A cross-section of such typical turbine1100is shown inFIG.18. As a comparative, Table 2 below provides the same parameters for operation of a high pressure, low velocity turbine according to the present disclosure. A cross-section of an exemplary turbine1200according to the disclosure is shown inFIG.19. As may be seen by comparing the conventional turbine1100to the turbine1200of the present disclosure, the turbine of the present disclosure may define a relatively smaller diameter due to the turbine of the present disclosure employing relatively shorter turbine blades2008F as compared to the turbine blades1108of the conventional turbine in some embodiments. In this regard, as shown in the following tables, the turbine blades2008F of the turbine1200of the present disclosure may define a relatively smaller average inner radius (i.e., from the center of the rotor2006F to the root of the turbine blade), average outer radius (i.e., from the center of the rotor to the tip of the turbine blade), and average radius (average of the inner and outer radii) as compared to the turbine blades1108of the conventional turbine1100in some embodiments. Also, the turbine1200of the present disclosure may define a relatively greater length to diameter ratio as compared to the conventional turbine1100. Further, the turbine1200of the present disclosure may include a relatively larger number of turbine blades2008F than the conventional turbine1100. Additionally, the diameter of the rotor2006F of the turbine1200of the present disclosure may be less than the diameter of the rotor1106of the conventional turbine1100. TABLE 1Conventional DesignParameterValueElectrical Generator Power Requirement2.5 × 108WTurbine Inlet Pressure15 bars(1.5 MPa)Turbine Outlet Pressure1 bar(0.1 MPa)Combustion Product Flow Temperature1,623 K(1,350° C.)Flow Density0.75kg/m3Flow Velocity700 mph(310 m/s)Turbine Length10mTurbine Diameter4mNumber of blades200 TABLE 2Inventive DesignParameterValueElectrical Generator Power Requirement2.5 × 108WTurbine Inlet Pressure300 bars(30 MPa)Turbine Outlet Pressure30 bar(3 MPa)Combustion Product Flow Temperature1,400 K(1,127° C.)Flow Density70kg/m3Flow Velocity100 mph(44 m/s)Turbine Length5mTurbine Diameter1.5mNumber of blades1,000 Many modifications and other embodiments of the disclosure set forth herein will come to mind to one skilled in the art to which the disclosure pertains having the benefit of the teachings presented in the foregoing descriptions. Therefore, it is to be understood that the disclosure is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. | 94,437 |
11859497 | The subject matter of the present disclosure is particularly pointed out and distinctly claimed in the concluding portion of the specification. A more complete understanding of the present disclosure, however, may best be obtained by referring to the detailed description and claims when considered in connection with the drawing figures, wherein like numerals denote like elements. DETAILED DESCRIPTION The detailed description of exemplary embodiments herein makes reference to the accompanying drawings, which show exemplary embodiments by way of illustration. While these exemplary embodiments are described in sufficient detail to enable those skilled in the art to practice the inventions, it should be understood that other embodiments may be realized and that logical changes and adaptations in design and construction may be made in accordance with the present inventions and the teachings herein. Thus, the detailed description herein is presented for purposes of illustration only and not of limitation. The scope of the present inventions is defined by the appended claims. Disclosed herein, according to various embodiments, is a seal assembly for gas turbine engines that includes a seal seat insert coupled to the rotating side of the seal assembly. In various embodiments, the seal seat insert provides various benefits over coatings or other applied materials. More specifically, the seal seat insert disclosed herein may inhibit premature wear and may extend/increase sealing performance of the seal assembly. While numerous details are included herein pertaining to assemblies and method pertaining to implementing the seal seat insert in a gas turbine engine, the seal seat insert and the associated methods/systems may be used in other seal assemblies. In various embodiments and with reference toFIG.1, a gas turbine engine20is provided. Gas turbine engine20may be a two-spool turbofan that generally incorporates a fan section22, a compressor section24, a combustor section26and a turbine section28. In operation, fan section22can drive fluid (e.g., air) along a bypass flow-path B while compressor section24can drive fluid along a core flow-path C for compression and communication into combustor section26then expansion through turbine section28. Although depicted as a turbofan gas turbine engine20herein, it should be understood that the concepts described herein are not limited to use with turbofans as the teachings may be applied to other types of turbine engines including three-spool architectures. Gas turbine engine20may generally comprise a low speed spool30and a high speed spool32mounted for rotation about an engine central longitudinal axis A-A′ relative to an engine static structure36or engine case via several bearing systems38,38-1, and38-2. Engine central longitudinal axis A-A′ is oriented in the z direction (axial direction) on the provided xyz axis. They direction on the provided xyz axis refers to a radial direction, and the x direction on the provided xyz axis refers to a circumferential direction. It should be understood that various bearing systems38at various locations may alternatively or additionally be provided, including for example, bearing system38, bearing system38-1, and bearing system38-2. Low speed spool30may generally comprise an inner shaft40that interconnects a fan42, a low pressure compressor44and a low pressure turbine46. Inner shaft40may be connected to fan42through a geared architecture48that can drive fan42at a lower speed than low speed spool30. Geared architecture48may comprise a gear assembly60enclosed within a gear housing. Gear assembly60couples inner shaft40to a rotating fan structure. High speed spool32may comprise an outer shaft50that interconnects a high pressure compressor52and high pressure turbine54. A combustor56may be located between high pressure compressor52and high pressure turbine54. The combustor section26may have an annular wall assembly having inner and outer shells that support respective inner and outer heat shielding liners. The heat shield liners may include a plurality of combustor panels that collectively define the annular combustion chamber of the combustor56. An annular cooling cavity is defined between the respective shells and combustor panels for supplying cooling air. Impingement holes are located in the shell to supply the cooling air from an outer air plenum and into the annular cooling cavity. A mid-turbine frame57of engine static structure36may be located generally between high pressure turbine54and low pressure turbine46. Mid-turbine frame57may support one or more bearing systems38in turbine section28. Inner shaft40and outer shaft50may be concentric and rotate via bearing systems38about the engine central longitudinal axis A-A′, which is collinear with their longitudinal axes. As used herein, a “high pressure” compressor or turbine experiences a higher pressure than a corresponding “low pressure” compressor or turbine. The core airflow C may be compressed by low pressure compressor44then high pressure compressor52, mixed and burned with fuel in combustor56, then expanded over high pressure turbine54and low pressure turbine46. Turbines46,54rotationally drive the respective low speed spool30and high speed spool32in response to the expansion. In various embodiments, geared architecture48may be an epicyclic gear train, such as a star gear system (sun gear in meshing engagement with a plurality of star gears supported by a carrier and in meshing engagement with a ring gear) or other gear system. Geared architecture48may have a gear reduction ratio of greater than about 2.3 and low pressure turbine46may have a pressure ratio that is greater than about five (5). In various embodiments, the bypass ratio of gas turbine engine20is greater than about ten (10:1). In various embodiments, the diameter of fan42may be significantly larger than that of the low pressure compressor44, and the low pressure turbine46may have a pressure ratio that is greater than about five (5:1). Low pressure turbine46pressure ratio may be measured prior to inlet of low pressure turbine46as related to the pressure at the outlet of low pressure turbine46prior to an exhaust nozzle. It should be understood, however, that the above parameters are exemplary of various embodiments of a suitable geared architecture engine and that the present disclosure contemplates other gas turbine engines including direct drive turbofans. A gas turbine engine may comprise an industrial gas turbine (IGT) or a geared aircraft engine, such as a geared turbofan, or non-geared aircraft engine, such as a turbofan, or may comprise any gas turbine engine as desired. Referring toFIG.2, a seal assembly100in an exemplary bearing compartment62is schematically shown. The bearing compartment62includes bearings64supporting rotation of a shaft66, according to various embodiments. The shaft66may be one of the inner shaft40and outer shaft50referenced above, or the shaft66may also be any other rotating shaft utilized within a gas turbine engine. A seal seat insert110may be coupled to the shaft66, and a seal body70(e.g., a static seal body) may be coupled to an engine static structure36. The seal body70may be configured to be biased into direct contact with the seal seat insert110to provide a sealing pressure between the seal body70and the seal seat insert110. The seal body70may be supported on a static structure36of the gas turbine engine. For example, the seal body70may be supported and/or retained by a seal holder72, and the seal holder72may be coupled to the engine static structure36via a biasing member74. The biasing member74may provide force to provide the sealing pressure between the seal body70and the seal seat insert110. In various embodiments, the seal seat insert110is coupled to a component102, such as a radially extending portion68of the shaft66. Said differently, the shaft66may include radially extending portion68, and the seal seat insert110may be coupled thereto. The radially extending portion68is supported on the rotating shaft66such that it rotates relative to the fixed seal body70, according to various embodiments. The radially extending portion68may include a radial surface facing axially aft. In various embodiments, and with momentary reference toFIG.3, the radially extending portion268of the shaft66defines a recess269, and the seal seat insert210is retained at least partially within the recess269. That is, the seal seat insert210may be received within the recess269via an interference fit. In various embodiments, the seal seat insert210may be retained within the recess269or otherwise generally coupled to the shaft66using one or more fasteners and/or retention features. In various embodiments, the seal seat insert210may be an annular structure that is press fitted within the annular recess269. In various embodiments, the seal seat insert210may be a tight fit against the outer diameter of the recess269, thus maintaining a proper fit/engagement throughout thermal and centrifugal transient conditions. Further, by so engaging the seal seat insert210within the recess269, the seal seat insert210may maintain a favorable compressive stress, the seal seat insert210may be protected from damage during installation, and/or may facilitate retention of the seal seat insert210within the recess269in the event the seal seat insert210is fractured. In various embodiments, one or more fasteners disposed in the outer diameter of the recess269may be utilized to facilitate retention of the seal seat insert210. In various embodiments, and with renewed reference toFIG.2, the seal body70is formed from a carbon material and provides a dry face seal that wears a predictable rate during operation of the gas turbine engine. In various embodiments, the seal body70provides sealing of the bearing compartment62against the environment surrounding the bearing compartment62. That is, the biasing member74may exert a force on the holder72and thereby the seal body70is forced against the seal seat insert110at a desired pressure. That is, the seal body70is a contact face seal, according to various embodiments. The pressure between the seal body70and the seal seat insert110may be within a desired range such that the seal body70and the seal seat insert110provide desired sealing performance (e.g., isolation of lubricant in the bearing compartment62). The seal body70may be made from carbon materials, such as graphite. In various embodiments, the seal seat insert110is made from a ceramic material or a ceramic matrix composite. In various embodiments, the seal seat insert110is made from silicon carbide and/or silicon nitride. In various embodiments, the seal seat insert110comprises a plurality of stacked, layered, and/or wrapped matrix plies and/or weaves. Seal seat insert110may be a ceramic matrix composite, such as a silicon-carbide/silicon-carbide matrix, carbon/carbon matrix, carbon/silicon-carbide matrix, alumina matrix, mullite matrix, or a zirconium diboride matrix. In various embodiments, the ceramic matrix composite material may comprise one or more of borides, carbides, oxides, and/or nitrides. In various embodiments the borides may be selected among a group comprising: ZrB2, HfB2, VB2, TiB2, TaB2, TaB, NbB2, NbB, VB2, TiB2, CrB2, Mo2B5, W2B5, Fe2B, FeB, Ni2B, NiB, LaB6, CoB, Co2B, or any other refractory boride. In various embodiments, the carbides may be selected among a group comprising: SiC, HfC, ZrC, C, B4C, SiOC, TiC, WC, Mo2C, TaC, NbC, or any other refractory carbide. In various embodiments, the oxides may be selected among a group comprising: HfO2, ZrO2, Al2O3, SiO2, class compositions including aluminosilicates, borosilicates, lithium aluminosilicates (LAS), magnesium aluminosilicates, barium magnesium aluminosilicates (BMAS), calcium aluminosilicates and other silica containing high temperature glasses, and/or other mixed metal oxides. In various embodiments, the nitrides may be selected among a group comprising: AlN, Si3N4, TaN, TiN, TiAlN, W2N, WN, WN2, VN, ZrN, BN, HfN, NbN, or any other refractory nitrides. In various embodiments, the CMC material may comprise mixed refractory nonoxides such as, for example, SiCN. With the seal seat insert110being formed of a ceramic or ceramic matrix composite material, the life of the seal assembly is improved. That is, because the seal seat insert110is thicker than, a conventional wear coating, the seal assembly100has an improved wear life because the seal seat insert110may be less susceptible to cracking and/or particle liberation, according to various embodiments. In various embodiments, the seal seat insert110is configured to operate effectively as a seal counterface at temperatures from about −40 degrees Fahrenheit (about 93 degrees Celsius) to about 350 degrees Fahrenheit (about 177 degrees Celsius). As used herein, the term “about” refers to plus or minus 5% of the indicated value. The interface between the seal seat insert110and the seal body70may generate substantial friction heat during operation of the gas turbine engine, and the ceramic/ceramic matrix composite may be well-suited for the operational temperatures. In various embodiments, and with reference toFIG.4, a method490of forming a seal between an engine static structure and a shaft of a gas turbine engine is provided. The method490may include supporting a seal body on the engine static structure at step492, coupling a seal seat insert to the shaft at step494, and generating a sealing pressure via direct contact between the seal body and the seal seat insert at step496. In various embodiments, coupling the seal seat insert to the shaft at step494comprises retaining the seal seat insert within a recess defined by the shaft. In various embodiments, step494may include heating the shaft to open/enlarge the recess to allow for insertion of the seal seat insert. Upon cooling, the seal seat insert may be retained within the recess with a tight fit. For example, the seal seat insert may be an annular structure, and the seal seat insert may be moved axially to be received into an annular recess defined by the shaft (e.g., a radially extending portion of the shaft). The seal seat insert may be made from at least one of a ceramic material and a ceramic matrix composite. In various embodiments, the seal seat insert is installed so as to be flush with the radially extending portion within which the seal seat insert is retained. Accordingly, the method may include polishing or otherwise grinding the seal seat insert to make the sealing interface surface flush with the radially extending portion. Benefits, other advantages, and solutions to problems have been described herein with regard to specific embodiments. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the disclosure. The scope of the disclosure is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” It is to be understood that unless specifically stated otherwise, references to “a,” “an,” and/or “the” may include one or more than one and that reference to an item in the singular may also include the item in the plural. All ranges and ratio limits disclosed herein may be combined. Moreover, where a phrase similar to “at least one of A, B, and C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C. The steps recited in any of the method or process descriptions may be executed in any order and are not necessarily limited to the order presented. Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Elements and steps in the figures are illustrated for simplicity and clarity and have not necessarily been rendered according to any particular sequence. For example, steps that may be performed concurrently or in different order are illustrated in the figures to help to improve understanding of embodiments of the present disclosure. Also, any reference to attached, fixed, connected, coupled or the like may include permanent (e.g., integral), removable, temporary, partial, full, and/or any other possible attachment option. Different cross-hatching is used throughout the figures to denote different parts but not necessarily to denote the same or different materials. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact. Surface shading lines may be used throughout the figures to denote different parts or areas but not necessarily to denote the same or different materials. In some cases, reference coordinates may be specific to each figure. Systems, methods and apparatus are provided herein. In the detailed description herein, references to “one embodiment”, “an embodiment”, “various embodiments”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element is intended to invoke 35 U.S.C. 112(f) unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises”, “comprising”, or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. | 19,290 |
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