ACTUATORS AND RELATED METHODS
Various embodiments of the present invention disclose enhanced and improved well production tools for increasing the stability of production zones in a wellbore. Various embodiments of the present invention generally relate to apparatuses, systems, and processes for efficiently and effectively isolating zones within a wellbore.
1 . An actuator module for actuating a downhole tool within a wellbore comprising:
a housing comprising a cylindrical chamber;
a piston disposed within the cylindrical chamber;
a linkage member operatively connecting the housing to the piston;
an incompressible fluid disposed within the cylindrical chamber on a first side of the piston;
a fluid path permitting a hydrostatic pressure of the wellbore to be applied to a second side of the piston and at least one surface of the linkage member, whereby the pressure of the incompressible fluid increases in response to an increase in the hydrostatic pressure of the wellbore;
a gas chamber at least partially filled with a compressible gas;
an isolation module comprising a pressure barrier between the cylindrical chamber and the gas chamber;
a controller comprising a microprocessor for running a real time program that causes the controller to generate an electrical output signal in response to at least one conditional event;
an electrical power source for powering the controller; and
an opening module for breaching the pressure barrier between the cylindrical chamber and the gas chamber in response to the electrical output signal generated by the controller, thereby causing actuation of the downhole tool.
2 . The actuator module as recited in claim 1 , further comprising at least one sensor interfaced with the controller for measuring at least one environmental parameter, and wherein the at least one conditional event is a function of at least one output from the at least one sensor.
3 . The actuator module as recited in claim 1 , wherein the isolation module further comprises a pressure retaining target section for retaining a differential pressure generated between the cylindrical chamber and the gas chamber.
4 . The actuator as recited in claim 1 , wherein the isolation module further comprises a valve seat for providing engagement with the opening module.
5 . The actuator as recited in claim 4 , wherein the opening module comprises a valve and a valve seal for engaging the valve seat.
6 . The actuator module as recited in claim 1 , wherein the opening module is an electrically activated disc cutter comprising a cutting dart for perforating the pressure barrier.
7 . The actuator module as recited in claim 1 , wherein the controller further comprises a communication receiver for receiving communication signals from a remote location and wherein the at least one conditional event is a function of at least the communication signal.
8 . The actuator module as recited in claim 1 , wherein the controller further comprises a communication transceiver for transmitting communication signals to a remote location, wherein the transmitted communication signal is an indication of the occurrence of the at least one conditional event.
9 . The actuator module of as recited in claim 1 , wherein the housing further comprises a shoulder for contacting the second side of the piston to limit the axial displacement of the piston and the linkage member.
10 . A method for actuating a downhole tool within a wellbore comprising:
operatively connecting at least one member of the downhole tool to the actuator module as recited in claim 1 ;
lowering the tool into the wellbore to a subterranean depth;
sensing the at least conditional event with the controller;
generating the electrical output signal with the controller in response to at least one conditional event sensed by the controller; and
breaching the pressure barrier between the cylindrical chamber and the gas chamber with the opening module in response to the electrical output signal generated by the controller; thereby causing actuation of the downhole tool.
11 . The method as recited in claim 10 , wherein operatively connecting at least one member of the downhole tool to the actuator module comprises operatively connecting the at least one member of the downhole tool to a surface of the piston.
12 . The method as recited in claim 11 , wherein lowering the downhole tool into the wellbore comprises lowering the downhole tool into the wellbore to a subterranean depth, wherein at least one surface of the piston that is not operatively connected to the at least one member of the downhole tool is exposed to the hydrostatic pressure of the wellbore.
13 . The method as recited in claim 12 , further comprising:
programming the microprocessor of the controller with a timing countdown;
starting the timing countdown; and
generating the controller electrical output signal with the controller in response to the expiration of the timing countdown.