An electrical-connection system for connecting a first cable to a second cable includes a central connector unit that attaches to cable-end connectors. Among other features, the central connector unit might include a curved surface, each of the cable-end connectors might include a grip mechanism. Generally, the electrical-connection system is configured to be positioned in a radial groove of a cylindrical body, such that an overall height of the system is maintained within space constraints.

BACKGROUND

In downhole-drilling operations an electrical connection typically connects internal drilling components with an external power source. Sometimes space constraints create a relatively narrowly defined region in which the electrical connection is allowed to be positioned.

SUMMARY

The present invention is directed to an electrical-connection system for connecting a first cable to a second cable, the electrical-connection system including a central connector unit that attaches to cable-end connectors. In one embodiment, the central connector unit includes a curved surface. In another embodiment, each of the cable-end connectors includes a grip mechanism. In a further embodiment, the electrical-connection system is configured to be positioned in a radial groove of a cylindrical body, such that an overall height of the system is maintained within space constraints.

DETAILED DESCRIPTION

The subject matter of embodiments of the present invention is described with specificity herein to meet statutory requirements. But the description itself is not intended to necessarily limit the scope of claims. Rather, the claimed subject matter might be embodied in other ways to include different elements or combinations of elements similar to the ones described in this document, in conjunction with other present or future technologies.

At a high level, an embodiment of the present invention is directed to an electrical-connection system for connecting cables in a radial groove of a cylinder. For example, the electrical-connection system includes a central connector unit that attaches to cable-end connectors. The central connector unit and the cable-end connectors are configured with various features that allow the overall height of the electrical-connection system to be maintained within space constraints of the radial groove.

Referring now toFIG. 1, an exemplary depiction is provided in which an electrical-connection system10is positioned within a radial groove11of a cylinder13. The cylinder13is only generically depicted for illustrative purposes, and in some embodiments the cylinder includes a downhole-drilling component positioned inside a casing. The electrical-connection system10might provide an electrical connection between one or more drilling components (e.g., inside a casing) and one or more external components (e.g., power source). The groove11and the cylinder13provide certain space constraints, such as a groove width15and a groove depth17(see alsoFIG. 2) defined by the inside diameter and outside diameter. In one embodiment, the electrical-connection system10includes features that allow the system10to maintain an overall height that does not exceed the space constraints.

FIG. 2depicts a cross-section of the cylinder13and groove11, as well as an illustrative view of the electrical-connection system10positioned within the groove. In addition,FIG. 2depicts a blown-up view in which the electrical-connection system10is enlarged for illustrative purposes, and the blown-up version of the electrical-connection system is identified by reference numeral10A.

InFIG. 2, the groove depth is defined by an internal diameter and an external diameter. In an embodiment of the present invention, the elements of the electrical-connection system10help to maintain the system10within the radial groove and help to reduce the likelihood that the system10will exceed the groove and extend out of the groove and beyond an outer surface19(FIG. 1.) of the cylinder13.

Referring toFIGS. 1-4, the system10includes a central connector unit12that connects to a first cable-end connector30and a second cable-end connector38. As previously mentioned, the first cable-end connector30and the second cable-end connector38attach to the central connector unit12in such a manner that the overall height of the electrical-connection system10is maintained within the radial groove11when the connectors30and38are connected to the central connector unit12and the system10is positioned in the groove11.

Various features contribute to maintaining a desired height of the system10, and some of these elements are listed in this portion of the description to provide a context for reading the subsequent portions of the description. But these elements will also be described in more detail in the subsequent portions. In one aspect, an angle28at which the connectors30and38attach to the central connector unit12helps maintain a desired height. InFIG. 2, while only the angle28is labeled with respect to the connector30, a similar angle measurement applies to the connector38. In another embodiment, a polarized connection (e.g., keyed) between the central connector unit12and the cable-end connectors30and38also helps to maintain a desired alignment of connectors, which helps to maintain a certain overall height. A further embodiment includes a curved surface of the system that has an arc radius similar to a radius of the internal diameter of the groove. Other features will become apparent to a reader after and because of reading this description.

In the drawings, the cable-end connectors30and38are depicted as female connectors that attach onto male connectors of the central connector unit12. However, in another embodiment, the cable-end connectors30and38might include a male connector (e.g., plug) that attaches to a female connector (e.g., socket) of the central connector unit.

The central connector unit12will now be described in more detail. The central connector unit12includes a shell22(FIG. 4) having a main body16and a first joining connector18and second joining connector20extending from the main body16. InFIG. 4the shell is identified by reference numeral22and is illustrated as walls (hatched portions) that are connected to one another to make up the central connector unit12. The main body16further comprises a front wall50A; a back wall50B (inFIG. 4the inside surface of the back wall is depicted, and the lead line of numeral58B references a top edge of the back wall); a right wall50C; a left wall50D; a top wall50E (FIG. 1); and a bottom wall50F. The terms “top,” “bottom,” “left,” “right,” “front,” and “back” are relative, are used merely for descriptive purposes with reference to the drawings, and are not meant to unduly limit the claims. In addition, the terms “top” and “bottom” are used to refer to walls that are generally opposed to one another, spaced apart, and generally face each other, and a similar interpretation should be given to the terms “left” and “right,” as well as “front” and “back.” But, these opposed walls are not necessarily parallel. For example, the right wall50C and left wall50D are not illustrated to be parallel, but they are still generally opposed, spaced apart, and face one another.

In an embodiment, the first joining connector18mirrors the second joining connector20. As such, for readability, sometimes only the first joining connector18or only the second joining connector20might be described, but it should be understood that the same description applies to the other (i.e., non-described) connector.

InFIGS. 3 and 4, the main body16includes a cavity24, which is at least partially defined by the front wall50A, the back wall50B, the right wall50C, the left wall50D, the top wall50E (FIG. 1), and the bottom wall50F. The cavity24might be filled with an epoxy or other medium.

In a further embodiment, the first joining connector18and the second joining connector20extend from the main body16at an angle28, which is depicted inFIG. 2. The angle28is defined by reference lines A and B. Reference line A extends generally perpendicular to a top wall32of the central connector unit12and bisects the central connector into a front half and a back half. Reference line B is axially aligned with the joining connector18, and the angle28is defined by the intersection of reference line A and B.

The angle28at which the joining connectors18and20extend from the main body16helps to control an angle at which the cable-end connectors30and38attach to the central connector unit12. Although the angle28is defined by reference lines A and B, other angles might also help define features of the central connector. For example, another angle29between reference line B and a line extending parallel to the top wall50E might also help define the central connector. Reference line A and a line extending parallel to the top wall50E form a 90 degree angle.

InFIG. 3, the bottom wall50F includes an external curved surface27(FIG. 3). The cross-section view inFIG. 4also depicts the curved nature of the external surface of the bottom wall50F. As depicted, the external curved surface27includes a generally concave configuration. In one embodiment, an arc radius of the external curved surface27substantially corresponds to a radius of the inner diameter of the cylinder13. As such, the external curved surface27is allowed to rest substantially flush against a base of the groove11.

In one embodiment, the angle28and arc radius of surface57is determined in-part based on the dimensions of the cylinder13and the groove11. For example, in one context the OD of the cylinder is about 5.750 inches, and the ID of the cylinder is about 4.375 inches, such that the angle28is about 66 degrees and the arc radius is about 2.1875 inches. In such an example, the first joining connector and the second joining connector would be angled at about 132 degrees with respect to one another. However, the dimensions of the cylinder might be smaller or larger, depending on the context, and the dimensions of the connector system can change accordingly. For example, if the ID is variable and the OD is constant, then angle28and arc radius of surface57can decrease accordingly.

In another embodiment, the central connector unit12includes a pin assembly, which includes a first set of one or more pins42and a second set of one or more pins44. The pin assembly includes one or more electrical conductors46that electrically couple the pins in the first joining connector18to the pins in the second joining connector20. In one embodiment, the pin assembly includes a 7-pin connector, as illustrated inFIG. 5. In other embodiments, a variety of different pin-assembly configurations might be utilized.

Various steps might be carried out when assembling the pin assembly and installing the pin assembly within the shell22. For example, the contacts might be tacked into place in the insulator with an appropriate epoxy prior to installation in the shell22. When the assembly is installed in the shell, the insulator might be tacked into the shell with an epoxy. In addition, as previously described, the cavity of the shell might also be filled with an appropriate epoxy. Other mechanism might also be used to couple the various components, such as mechanical fasteners.

As previously described, the first cable-end connector30attaches to a first joining connector18. In one embodiment, an interface between the cable-end connector30and the joining connector18includes a first set of one or more keys that aligns with a first set of one or more keyways. For example, the first joining connector18includes an outer surface31, and a first set of one or more keys32A-C radially extend from the outer surface31. In addition, the cable-end connector30includes a generally tubular body having an inner surface33, which includes a first set of one or more keyways34A-C (seeFIG. 6) that mates with the first set of one or more keys32A-C.

Among other things, the mating relationship between the keys and keyways helps to prevent the components of the electrical-connection system10from rotating relative to one another when connected and helps to properly align the components. For instance, the keys might be unevenly spaced with respect to one another in a manner that corresponds with the keyways, such that only one orientation of the cable-end connector couples to the central connector unit. An exemplary spacing is depicted inFIG. 5in which keys32B and32C are closer together to one another than to the other key32A. That is, reference lines C, D, and E represent a general axial relationship between keys32A,32B, And32C, and lines C and D intersect at an angle35that is larger than an angle37between lines D and E. As such, a corresponding keyway configuration can only mate with the keys when the keyways are oriented in a similar manners (i.e., the upper keyway is spaced further apart from the two lower keyways than the two lower keyways are to each other).

Although the drawings depict keys on the joining connector18and20and keyways in the cable-end connector, in an alternative embodiment the keys might extend inward from the inside surface of the cable-end connector and the joining connector might include the corresponding keyways. In addition, although the drawings depict three keys and three keyways, as few as one key and one keyway or more than three keys and keyways might be employed.

Other features of the central connector unit12might also contribute to maintaining the connection within space constraints of the groove11. For example, the central connector unit12might include a ratio of dimensions that help to maintain the system10within certain space constraints. As such the main body16might include a height54(FIG. 4) from the bottom wall50F to the top wall50E, a length52(FIG. 4) from an end of one joining connector18to an end of the other joining connector20, and a width56(FIG. 5). In one embodiment, a ratio of two or more of these dimension relative to one another help to maintain the system10within the space constraints of a groove. For example, in one embodiment, the central connector unit12includes a height to length ratio of about 0.49:1.96. In another embodiment, the central connector unit12includes a height to width to length ratio of about 0.49:0.51:1.96. In another embodiment, these ratios can be extrapolated to be applied to grooves having various groove sizes.

Referring now toFIGS. 6-8, the cable-end connector30will be described in more detail. The cable-end connector30includes a cable-insertion end60and a connector-attachment end62. Generally, a cable66can be inserted into the cable-insertion end60and coupled to a pin assembly68, which is proximate to the connector-attachment end62. The pin assembly68mates with the set of one or more pins42of the central connector unit12when the connector-attachment end62is coupled to the joining connector18. As such, the cable-end connector30functions to couple the cable66to the central connector unit. When a plurality of cables are coupled to the central connector unit (by way of respective cable-connection ends), the central connector unit provides an electrical connection between the plurality of cables.

The cable-end connector30includes various features that assist with connecting or disconnecting within a cylindrical groove. For example, the cable-end connector30includes a radially extending gripping mechanism36. The radially extending gripping mechanism includes a protruding member that extends outward from a surface70of the cable-end connector. As depicted inFIGS. 6-8, the radially extending gripping mechanism36includes a first surface72that faces towards the connector-attachment end62and that includes a generally concave configuration. In addition, the radially extending gripping mechanism36includes a second surface74(FIG. 8) that faces towards the cable-insertion end60and that includes a generally convex configuration. The orientation and curvature of the surfaces72and74helps to improve the ability of a user to grip the cable-end connection when connecting and disconnecting.

In a further embodiment, features of the system10help to maintain the gripping mechanism36within a groove11. For example, as previously described, the key and keyway interface is polarized and facilitates proper alignment in order for the cable-end connector30to couple with the joining connector18. As such, when properly aligned, the gripping mechanism36extends towards an opening of the groove, as opposed to interfering with side walls of the groove. In addition, the key and keyway help to impede the cable-end connector30from rotating relative to the joining connector18, since rotation could cause the gripping mechanism36to interfere with the groove walls.

In addition, dimensions of the gripping mechanism36also help to maintain an overall height of the system10within the space constraints of the groove11. For example, in one embodiment, the gripping mechanism includes a height of about 0.093 inches. As such, the height of the gripping mechanism helps to limit portions of the system10extending beyond a groove when the system10is positioned within the groove.

As depicted inFIGS. 7 and 8, the cable-end connector30includes a first shell78and a second shell80. In addition, the first shell78and second shell80are mechanically coupled, such as via threads. For instance, internal threads82of the first shell78are depicted inFIG. 8. However, other mechanical fasteners might also be utilized to connect the first shell to the second shell. In an alternative embodiment, the shells78and80might be coupled by some other mechanisms, such as by an adhesive, weld, or other mechanism. In another embodiment, the shells78and80are combined into a single shell, such as by casting.

The cable-end connector30includes an overall length86from the cable-insertion end60to the connector-attachment end62. In one embodiment, the length82is configured to help keep the system10within certain space constraints created by the groove11. For example, in one instance, the length82helps to keep both cable-insertion ends60from extending beyond the outer diameter of the cylinder. In one embodiment, the length is about 1.303 inches.

The cable-end connector30also includes a diameter84. In one embodiment, the diameter84is configured to help keep the system10within certain depth17and width15constraints created by the groove11. In one embodiment, the diameter is about 0.435 inches.

The cable66and pin assembly68might be secured within the cable-end connector30using various elements. For example, similar to the joining connectors, the insulator potting well might be filled with an epoxy prior to installation in the connector-attachment end62in order to hold the contacts in place. In addition, a canted spring90or other retaining mechanism might also be installed within the connector-attachment end prior to installing the insulator. The canted spring90or other retainer engages a lip or groove92in the outer surface31of the joining connector18. Once the insulator and contacts are installed, the shells78and80might be at least partially filled with one or more types of epoxy. For example, the shell78might be filled with a first type of epoxy, which is filled up to an interface with the shell80, which might be filled with a second type of epoxy.