Patent Publication Number: US-10327357-B2

Title: Thermal conduction to a cylindrical shaft

Description:
FIELD 
     The present disclosure relates to canister system and, more particularly, relates to a thermal conduction systems for use in a canister system. 
     BACKGROUND 
     This section provides background information related to the present disclosure which is not necessarily prior art. 
     Deep sea operations are an important part of many industries today. This is especially true in the oil and gas industry. As global energy demands increase and land-based oil and gas deposits decrease, there is a renewed demand to produce oil and gas from offshore locations. In fact, in 2007, more than a third of all produced oil was pumped from offshore locations. With advancements in shale production, the location of these oil production rigs is moving into deeper waters. 
     In the past, much of the equipment used in oil and gas production was located at the water surface on specially designed rigs. However, with advancements of deep water equipment, many of the required pumps, compressors, and mixing systems are now located subsurface, such as on the ocean floor. However, at these depths, the deep water equipment, including control and/or monitoring electronics, must be designed and configured to withstand the enormous water pressures exerted thereon. In fact, in some deep water applications, water pressure can exceed several hundred bar and water temperature can approach freezing (32 degrees Fahrenheit). 
     There are significant benefits in having control and/or monitoring electronics at subsurface locations, and particularly on the ocean floor. On site (e.g. subsurface) location of this equipment ensures that communication systems and lines are less likely to fail due to shortened communication lines and, thus, such systems can provide active control and monitoring of the associated equipment to ensure safe and reliable operation of the production equipment. 
     However, to enhance reliability of the control and/or monitoring electronics in such an extreme pressure and temperature environment, it is necessary to provide a protective enclosure that can stave off detrimental environmental effects, such as pressure and overheating, and further provide a safe and reliable enclosure and connection methodology to minimize the need for maintenance and/or replacement that can lead to significant operational downtime. 
     For at least these reasons, there appears to be a need to provide a canister system capable of overcoming the disadvantages of the prior art. 
     SUMMARY 
     This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. 
     According to the principles of the present teachings, a canister system having a cylindrical housing and a modular electronic rack system disposed within the cylindrical housing is provided having advantageous construction and operation. The modular electronic rack system includes a thermal contact member that is in at least selective physical contact with an interior surface of the cylindrical housing to permit conductive heat transfer there through. An input/output device extends along at least a portion of the modular electronic rack system and includes a power input and a signal output electrically coupled thereto. A plurality of electronic slots disposed at a position generally along the modular electronic rack system is provided. 
     Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
    
    
     
       DRAWINGS 
       The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. 
         FIG. 1  is a schematic view illustrating a canister system according to the principles of the present teachings; 
         FIG. 2  is a front perspective view illustrating a modular electronics rack system according to the principles of the present teachings; 
         FIG. 3  is a rear perspective view illustrating a modular electronics rack system according to the principles of the present teachings; and 
         FIG. 4  is an enlarged perspective view illustrating a portion of the modular electronics rack system having a wedge lock system according to the principles of the present teachings. 
     
    
    
     Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
     DETAILED DESCRIPTION 
     Example embodiments will now be described more fully with reference to the accompanying drawings. 
     Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. 
     The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore 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. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed. 
     When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. 
     Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments. 
     Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. 
     As discussed herein, to enhance reliability of the control and/or monitoring electronics in such an extreme pressure and temperature environment, it is necessary to provide a protective enclosure that can stave off detrimental environmental effects, such as pressure and overheating, and further provide a safe and reliable enclosure and connection methodology to minimize the need for maintenance and/or replacement that can lead to significant operational downtime. 
     To this end, according to the principles of the present teachings, a cylindrical canister system  10  is provided that is capable of overcoming the disadvantages of the prior art. Specifically, the canister system  10  of the present teachings employ a plurality of innovations that minimize or eliminate the use of features or systems that traditionally fail in deep sea or other extreme environments. It should be understood, however, that although many innovations will be described in connection with the present disclosure, these innovations should not be regarded as being required in each and every embodiment. Therefore, claims directed to portions of the present disclosure are presented that do not require all elements described herein, unless otherwise noted. 
     Although the present teachings are described in connection with deep sea applications, it should also be appreciated that the principles of the present teachings may find utility in a wide range of applications, including any environment where pressure, temperature, vibration, debris, contamination, and other environmental effects may lead to reduced operational reliability and/or failure. The principles of the present teachings are particularly well suited for marine applications, and thus the systems are designed and configured for waterproof operations. 
     With particular reference to  FIG. 1 , canister system  10 , according to some embodiments of the present teachings, can comprise a housing  12 . In some embodiments, housing  12  is a cylindrical member having an elongated shape defining a cylindrical sidewall  16  having opposing ends  18 ,  20 . In some embodiments, bottom end  18  can be integrally formed with sidewall  16  to form a continuous member. Bottom end  18  can terminate and enclose the respective end of housing  12  via a bottom cap or integrally-formed surface, thereby forming an internal volume  22  within housing  12 . For purposes of the present disclosure, bottom end  18  refers to both the locational end of cylindrical sidewall  16  and the associated cap or closure surface formed there at. Internal volume  22  is defined by an interior surface  24  of cylindrical sidewall  16  and an interior surface  26  of bottom end  18 . 
     In some embodiments, housing  12  further comprises a head member  14  that is connectable with cylindrical sidewall  16 . In some embodiments, head member  14  is releasably or detachably coupled to cylindrical sidewall  16  at top end  20  to permit access to internal volume  22  of canister system  10  after assembly. To this end, head member  14  can be coupled to cylindrical sidewall  16  in such a way as to permit convenient detachment of head member  14  from sidewall  16 , such as via the use of a threaded system or other releasable connection system. However, in some embodiments requiring a more permanent connection between head member  14  and cylindrical sidewall  16 , alternative coupling means can be used, including, but not limited to, welding, bonding, and the like. 
     With continued reference to  FIG. 1 , in some embodiments, canister system  10  can comprise a locking or mating mechanism  28  that is engageable with a corresponding system for mounting and/or anchoring canister system  10  in a predetermined position or location. In some embodiments, mating mechanism  28  can comprise a plurality of projections that can be received within corresponding features of a base system. 
     Housing  12 , including cylindrical sidewall  16 , bottom end  18 , and head member  14 , is configured to withstanding the associated environmental conditions in which it is intended to be disposed. For example, in some embodiments, housing  12  is configured to withstand the extreme water pressure and salinity of deep sea operations. To this end, housing  12  can include increase wall thickness and corrosion treatment. By way of non-limiting example, in some embodiments, canister system  10  is configured to withstand pressures at depths of about 500 m-3000 m (or more) in the range of about 700 psi to about 5000 psi (or more). More particularly, in some embodiments, ruggedized canister system  10  is configured to withstand pressure in the range of about 1400 psi to about 4500 psi. Moreover, in some embodiments, ruggedized canister system  10  is particularly configured to withstand environmental contaminants including, but not limited to, corrosion, chemical degradation, and the like. 
     Modular Electronics for Cylinders 
     In conventional designs, underwater electronic systems often employ various cables and/or wiring to electrically interconnect the electronics within the system. These cables and wires are typically routed throughout the canister as necessary to achieve the desired connection protocol, which results in excessive complexity and increased potential for connection failures and associated downtime due to the plurality of connection joints. It has been determined that due to the nature of deep sea applications and other extreme environments, such cables and wires should be minimized or avoided to in turn minimize or avoid susceptible connection joints. 
     To this end, in some embodiments, the present teachings provide modular electronics and an associated rack system to permit simplified interconnection of the electronics without unnecessary cabling and wiring. As illustrated in  FIGS. 2 and 3 , in some embodiments, the present teachings provide a modular electronic rack system  30  that defines a number of benefits over the prior art. 
     Modular electronic rack system  30  is configured to be disposed within interior volume  22  of housing  12  and support a plurality of electronics modules. To this end, in some embodiments, modular electronic rack system  30  can comprise a cage-type system having a plurality of individual electronic slots  32  for receiving a respective one of a plurality of modular electronic cards  34 . Electronic cards  34  can each be electrically coupled to a high density input/output (I/O) board  36  via known connection methods, such as a backplane that directly routes signals to the top of the canister. The plurality of modular electronic cards  34  can comprise any one of a number of electronic cards, including printed circuit boards and the like. 
     In some embodiments, modular electronic rack system  30  can comprise a structural cage assembly having a plurality of rib members  38  radiating outwardly from a backplane  40  (see  FIG. 3 ). Each of the plurality of rib members  38  extends from backplane  40  in a direction generally orthogonal to a longitudinal axis A-A of backplane  40 . A proximal end of each rib member  38  can be fixedly coupled or integrally formed with backplane  40  and arcuately extend therefrom to a forward position. That is, when viewed from above, each rib member  38  can define a circular profile that closely conforms to that of interior surface  24  of cylindrical sidewall  16 . 
     In some embodiments, rib member  38  can define a rear transition region  42  adjacent backplane  40  that transitions the backplane surface to an arcuate section or surface  44 . In some embodiments, arcuate section  44  is sized and shaped to closely conform to interior surface  24  of sidewall  16  of housing  12 . In this way, arcuate section  44  of rib members  38  can physically engage and/or contact interior surface  24  of sidewall  16  to provide structural resistance to compression of housing  12  caused by external pressure (e.g. underwater pressure). Accordingly, in some embodiments, modular electronic rack system  30  is configured and adapted to withstand compression force exerted on housing  12  and transferred those forces to modular electronic rack system  30 . In this way, modular electronic rack system  30 , in some embodiments, can serve as both a modular electronics rack system supporting a plurality of electronic cards  34  and electronically coupling the same and further providing substantial structural support to housing  12 . In some embodiments, modular electronic rack system  30  is capable of withstanding up to about 100% of the present compressive force. 
     In some embodiments, rib members  38  can further extend from arcuate section  44  to a generally flat surface  46 . As illustrated in  FIG. 2 , flat surface  46  can be formed in a portion of rib members  38 , while other rib members  38  can include a continued arcuate section  44  terminating at a front transition region  48 . In some embodiments, flat surface  46  and/or front transition region  48  of each rib member  38  can be joined along a sternum section  50 . Sternum section  50  provides, at least in part, structural support for rib members  38  and the overall structure of modular electronic rack system  30 . In some embodiments, sternum section  50  can comprise a pair of interior wall members  52  extending inwardly from flat surface  46  and/or front transition region  48  to define a pair of inner walls on opposing sides of individual electronics slots  32 . Interior wall members  52  can terminate at a position adjacent an inner surface  54  of backplane  40 . Depending on the method of manufacturing employed (e.g. casting), interior wall members  52  can be integrally formed with backplane  40 . 
     In some embodiments, the plurality of individual electronic slots  32  is arranged in a stacked configuration. Each of the plurality of individual electronic cards  34  can be electrically coupled to each of the corresponding electronic slots  32  of I/O board  36  extending along backplane  40 . In this way, I/O board  36  and/or individual electronic slots  32  can be coupled to backplane  40 , such as via alignment and/or keying pins  56  extending through backplane  40 . It should be understood, however, that other configurations, such as vertically-oriented stacking or other orientations, are anticipated. 
     In some embodiments, I/O board  36  can define one or more printed circuit boards having individual electronic slots  32  disposed thereon and integrated therewith, thereby permitting electrical interconnection and/or coupling of each of the individual electronic slots  32  without the need for separate cabling or wires. In such embodiments, benefits can be realized through reduced complexity and failure modes. However, it should be understood that I/O board  36  can also be configured to have other connecting systems, such as ribbon cables, PWB flex cables and the like. 
     In some embodiments, as illustrated in  FIG. 3 , a power input  60  can further be employed and operably coupled to I/O interface  36 /backplane  40 . Specifically, in some embodiments, power input  60  can be operably coupled to backplane  40  to supply power from an external source to components disposed within canister system  10 , such as the plurality of electronic cards  34 . To this end, in some embodiments, power input  60  can be disposed along a bottom portion of modular electronic rack system  30  to minimize the distance interface between power input  60  and I/O interface. In this way, power input  60  can be directly mounted and electrically coupled to I/O interface to minimize or eliminate the use of cabling or wiring. Moreover, in this way, the relative orientation of power input  60  can be fixed relative to I/O board  36  for improved dependability and reliability. Still further, the relative orientation of power input  60  relative to bottom end  18  of housing  12  can be fixed relative to an external throughput connector extending through housing  12 , as will be discussed herein. However, it should be understood that power input  60  can also be disposed along a top portion of modular electronic rack system  30 , if desired. 
     Similarly, in some embodiments as illustrated in  FIGS. 1-3 , an I/O interface head  62  can be further employed and operably coupled to I/O interface board  36 . Specifically, in some embodiments, interface head  62  (shown in  FIG. 1 ) can be operably coupled to I/O interface board  36  to permit input/output communications with sensors and/or devices external to the components disposed within canister system  10 , such as the plurality of electronic cards  34 . To this end, in some embodiments, interface head  62  can be disposed along a top portion of modular electronic rack system  30  to minimize the distance interface between interface head  62  and I/O board  36 . In this way, interface head  62  can be directly mounted and electrically coupled to I/O interface board  36 , such as via an interface adapter board  64  (shown in  FIG. 3 ), to minimize or eliminate the use of cabling or wiring. Moreover, in this way, the relative orientation of interface head  62  can be fixed relative to I/O interface board  36  for improved dependability and reliability. Still further, the relative orientation of interface head  62  relative to head member  14  of housing  12  can be fixed relative to an external throughput connector extending through housing  12  (e.g. head member  14 ), as will be discussed herein. 
     Thermal Conduction to a Cylinder or Cylindrical Shaft 
     In some embodiments, it may be desirable to dissipate heat that builds up or is contained within canister system  10 . Specifically, in some embodiments, heat can be dissipated through conduction via physical contact between modular electronic rack system  30  contained within housing  12  and housing  12 . 
     In order to achieve the necessary physical contact between modular electronic rack system  30  and internal surface  24  of housing  12 , in some embodiments, rib members  38  or other structure of modular electronic rack system  30  can be sized to closely conform with internal surface  24  to achieve conductive contact to permit heat energy to flow between modular electronic rack system  30 , housing  12 , and the environment surrounding canister system  10  (e.g. water). In this way, heat generated through the operation of electronic cards  34  and other components can radiate and/or conduct to modular electronic rack system  30 . Heat contained in modular electronic rack system  30  can then be conducted to housing  12  and then to the environment surrounding canister system  10 . 
     In some embodiments, the surface area in contact between modular electronic rack system  30  and housing  12  is sufficient to effect the necessary cooling of electronic cards  32  to maintain a predetermined operational temperature. However, as it should be appreciated, the sufficiency of this arrangement is dependent on the amount of heat generated by the plurality of electronic cards  32  and other components and the heat transfer potential to the environment surrounding the canister system  10 . 
     In some applications, additional heat transfer rates may be desired. In some embodiments, a conduction plate, thermal contact, or other feature can be used between modular electronic rack system  30  and housing  12  to increase the surface area contact therebetween to improve heat transfer. 
     In some embodiments, the contact between modular electronic rack system  30  and housing  12  can be enhanced by virtue of the compression of housing  12  when exposed to increased external pressure (e.g. water pressure). In this way, increased external pressure can cause compression of housing  12  sufficient to force contact between housing  12  and modular electronic rack system  30 , as described herein. Such contact increases the contact area and, thereby, increases heat transfer. 
     Similarly, in some embodiments, alternative features can be used to enhance the contact between modular electronic rack system  30  and housing  12  in conditions absent from sufficient external compressive forces, such as low pressure environments. In such applications, as illustrated in  FIG. 4 , a wedge lock system  70  that is capable of exerting a force upon modular electronic rack system  30  to force modular electronic rack system  30  against internal surface  24  of housing  12  to achieve a predetermined thermal/physical contact therebetween. Wedge lock system  70  can comprise a wedge cam member  72  being coupled to modular electronic rack system  30 , such as along the opposite side of the thermal interface. In some embodiments, actuation of an adjustment device or screw  74  can actuate wedge cam member  72  translate and exert a force between modular electronic rack system  30  and a feature of housing  12 . 
     Alignment Mechanism for Cabling to a Cylinder Head 
     As should be appreciated, electrical connections to I/O board  36  and/or power input  60  must be routed to, from, and/or through housing  12 . Due to the aforementioned environment in which the present teachings are particularly suited (e.g. marine applications), it should be appreciated that these electrical connections must permit electrical transmission and/or communication, and must also be sufficient to withstand the pressure, temperature, and any contaminant present in the surrounding environment. 
     Therefore, electrical connections to I/O board  36  and/or power input  60  can be routed through housing  12  via sealed connectors  80  to establish and maintain electrical communication with modular electronic rack system  30  and/or electronic cards  32 . That is, sealed connectors  80  are configured to reliably establish electrical communication from a position external to canister system  10  to a position within canister system  10 . 
     In some embodiments, as illustrated in  FIG. 1 , sealed connectors  80  can comprise a plurality of contacts  82  extending from electrical systems, such as I/O board  36  and/or power input  60 . In some embodiments, the plurality of contacts  82  can comprise Ethernet, RS232, RS485, CAN and digital and analog I/O inputs and outputs. 
     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.