Apparatus and methods for controlling and communicating with downwhole devices
Apparatus and methods for controlling and communicating with one or more tools in a downhole tool string including a tractor, an auxiliary tractor tool, a logging tool, a safety sub, a release mechanism, a unit containing sensors for monitoring downhole conditions, a setting tool, and a perforating gun. Also provided are apparatus and methods for controlling and communicating with one or more perforating guns, release devices, and explosive devices in a string to be lowered into a wellbore. Control and communication are accomplished by sending signals from the surface to control switches in the control units on the tool, with redundant switches for safety, to state machines in the respective control units, each state machine returning a signal verifying switch status to the surface. Control and power functions are accomplished with voltage of different polarities for safety.
1. A switch unit responsive to downlink communication signals for use in a perforating gun, release device, or explosive device for lowering into a wellbore comprising:
a switch for activating the perforating gun, release device, or explosive device;
a microprocessor operably connected to said switch; and
first and second uplink communications transmitters operating at low and high current levels, respectively,
said microprocessor selecting either the first or the second current level transmitter depending upon whether downlink communication signals are transmitted before or after lowering into a wellbore.
2. The switch unit of claim 1 wherein the uplink communications transmitter is selected by either (a) a pre-check controller, surface controller, or surface computer or (b) a pre-check controller, surface controller, and surface computer by downlink communication signals to said microprocessor.
3. The switch unit of claim 1 wherein said microprocessor conducts a check to determine whether said switch is open or shorted.
4. The switch unit of claim 1 wherein the current level of uplink communications from the first transmitter is in the range of from about 4 milliamps to about 15 milliamps.
5. The switch unit of claim 1 wherein the second transmitter is selected for uplink communications after lowering the perforating gun, release device, or explosive device into the wellbore.
6. The switch unit of claim 1 wherein the current level of uplink communications from the second transmitter is in the range of from about 10 milliamps to about 100 milliamps.
7. An explosive initiator integrated into a switch unit for use in connection with a perforating gun to be lowered into a wellbore on a cable comprising:
a receiver for receiving a downlink signal through a cable in communication with a surface;
first and second transmitters operating at low and high current levels for transmitting uplink signals through the cable;
a microprocessor in electrical communication with said signal receiving means and said first and second transmitters including a state machine for validating a signal from said signal receiving means by identifying a status of the switch unit and one or more valid commands for each status of the switch unit and for returning an uplink signal using either said first or said second transmitter through the cable;
a switch responsive to an output from the microprocessor when a signal is validated by the state machine; and
an explosive initiator operably connected to said switch.
8. The explosive initiator of claim 7 wherein the microprocessor is adapted to check the status of the switch.
9. The explosive initiator of claim 7 wherein said first and second transmitters transmit uplink signals at different current levels.
10. The explosive initiator of claim 9 wherein the current level of the uplink signal is controlled from a surface computer.
11. The explosive initiator of claim 7 wherein the uplink signal further comprises the status of the switch unit.
12. The explosive initiator of claim 7 wherein the uplink signal further comprises an identifier for the switch unit.