High Temperature Control System

THE CHALLENGE

A client approached us with a request to design a control system for an innovative downhole tool they were developing.

Designing a high-temperature electronic control system for the oil/downhole industry posed several formidable challenges.

The system needed to withstand extreme temperatures exceeding 150°C, endure shock and vibration, and operate reliably in a hostile downhole environment.

Additionally, the system had to accommodate varying motor drive requirements, maintain modularity for flexibility, and ensure ease of maintenance by non-electronics experts.

Battery performance, component reliability, and pressure considerations further complicated the task.

THE SOLUTION

To address these challenges, we adopted a modular design approach, developing subsystem modules such as CPU boards, motor drive control boards, and sensor boards connected via a carrier COMM’s board.

This modular design facilitated easy replacement and maintenance.

Careful sourcing and analysis led to the integration of high-temperature components, while power usage concerns (as the system is battery powered) were mitigated by a low-power sleep mode for extended storage (uA quiescent current), with onboard sensors used for tool + electronics re-activation.

THE IMPLEMENTATION

Our implementation involved rigorous research and development, testing various electronic components and battery configurations to ensure real-world performance and reliability.

The design process encompassed iterative stages, culminating in a production-ready system capable of withstanding the demanding downhole conditions.

Temperature, pressure, shock, vibration, and operational data are logged in non-volatile memory for analysis and future development.

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THE RESULTS

The resulting control system met and exceeded expectations, providing a reliable solution for downhole applications.

Its modular design facilitated adaptability to different tool configurations and control requirements, while the inclusion of high-temperature components ensured longevity and robustness.

Clients benefited from the system’s flexibility, serviceability, and expandable nature, enabling them to program custom tool routines.

Furthermore, the logged data proved invaluable for ongoing tool development and monitoring, enhancing client understanding of tool usage and performance.

Looking ahead, ongoing developments include support for power and communication integration within drill pipes and the pursuit of extended temperature operation up to 200°C, with specific circuits already in development pending advancements in battery technology.

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Frequently Asked Questions

What distinguishes us as a high-quality electronics designer?

When it comes to being a top-tier electronics designer, Jubilee Electronics stands head and shoulders above the rest. We pride ourselves on our unwavering dedication to innovation, precision, and uncompromising excellence. Our team of seasoned engineers doesn’t just possess expertise; they’re veritable maestros in the world of technology, always at the forefront of industry trends.

How is do you ensure quality of manufactured products?

At Jubilee Electronics, we ensure the exceptional quality of our manufactured products through a meticulous and comprehensive approach. Our stringent quality control measures are integrated at every stage of the design and manufacturing process. This includes rigorous testing protocols, adherence to industry standards, and the use of cutting-edge technologies. By maintaining a commitment to precision and excellence, we guarantee that each product meets the highest standards of performance and durability.

What industries do you have experience in?

Jubilee Electronics boasts extensive experience across a diverse range of industries. Our expertise spans but is not limited to aerospace, healthcare, automotive, industrial automation, and telecommunications. This versatile proficiency enables us to tailor our high-quality electronic solutions to the unique demands of each industry we serve.

Is product testing and compliance handled in house?

Absolutely. At Jubilee Electronics, we manage product testing and compliance in-house. Our state-of-the-art facilities are equipped with the necessary resources and testing equipment to conduct thorough assessments and ensure that our products adhere to all relevant regulatory standards and certifications. This integrated approach allows us to maintain control over the quality and compliance of our products throughout the entire manufacturing process.

Do you manufacture the circuit boards in house?

Yes, we take pride in our end-to-end capabilities, and this includes the in-house manufacturing of circuit boards. Our dedicated manufacturing facilities are equipped with advanced machinery and a skilled workforce to produce high-quality circuit boards with precision. This integrated approach not only ensures quality control but also streamlines the production process, allowing us to meet the specific needs of our clients efficiently.

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