Battery system for downhole drilling tools

Abstract

A system, assembly, module, and method are disclosed for powering a downhole tool in a drilling operation. The system may include a reusable battery module and/or controller to operate multiple batteries.

What is claimed: 
     
         1 . A downhole tool system for a drilling operation that includes a drill string configured to form a borehole in an earthen formation, the downhole tool comprising:
 a downhole tool configured to be disposed along the drill string; and   a battery assembly configured to power the downhole tool, the battery assembly including;
 a battery coupled to the downhole tool, the battery having a first end, a second end opposite to the first, and a memory unit integral with the first end of the battery, wherein the memory unit includes stored therein information related to the battery; and 
 a module removably coupled to the first end the battery, the module including a processor configured to monitor information related to the battery, and a communications unit configured to transmit the information related to the battery at least between the memory unit and the processor when the module is coupled to the first end of the battery and the processor is in electronic communication with the memory unit of the battery. 
   
     
     
         2 . The downhole tool system of  claim 1 , wherein the information related to the battery includes an estimated remaining capacity of the battery. 
     
     
         3 . The downhole tool system of  claim 1 , wherein the module further includes a current sensor configured to monitor a current draw of the battery over a period of time. 
     
     
         4 . The downhole tool system of  claim 3 , wherein the module is configured to transmit the current draw of the battery to the memory unit so that the information stored in the memory unit includes the current draw. 
     
     
         5 . The downhole tool system of  claim 1 , wherein the module further includes a temperature sensor configured to monitor a temperature of the battery. 
     
     
         6 . The downhole tool system of  claim 5 , wherein the module is configured to transmit the temperature of the battery to the memory unit such that information stored in the memory unit includes the temperature of the battery. 
     
     
         7 . The downhole tool system of  claim 1 , wherein the module further includes a voltage sensor configured to monitor voltage data of the battery over a period of time. 
     
     
         8 . The downhole tool system of  claim 7 , wherein the module is configured to transmit the voltage data of the battery over the period of time to the memory unit such that the information stored in the memory unit includes the voltage data. 
     
     
         9 . The downhole tool system of  claim 1 , wherein the module further includes an accelerometer configured to monitor at least one of vibration and shock of the battery over a period of time. 
     
     
         10 . The downhole tool system of  claim 9 , wherein the module is configured to transmit the at least one of the vibration and shock of the battery to the memory unit such that information stored in the memory unit includes the vibration data. 
     
     
         11 . The downhole tool system of  claim 1 , wherein the battery includes a pressure sensor that is configured to detect a pressure change within the battery. 
     
     
         12 . The downhole tool system of  claim 1 , wherein the battery assembly is a first battery assembly, the battery is a first battery, the memory unit is a first memory unit, the module is a first module, the processor is a first processor, and the communications unit is a first communications unit, wherein the downhole tool assembly further comprises:
 a second battery assembly configured to power the downhole tool, the second battery assembly including;   a second battery coupled to the downhole tool, the second battery having a first end, a second end opposite to the first end of the second battery, and a second memory unit integral with the first end of the second battery, wherein the second memory unit includes stored therein information related to the second battery; and   a second module removably coupled to the first end the battery, the second module including a second processor configured to monitor an estimated capacity of the second battery, and a second communications unit configured to transmit the estimated capacity at least between the second memory unit and the second processor when the second module is coupled to the first end of the second battery and the second processor is in electronic communication with the second memory unit.   
     
     
         13 . The downhole tool system of  claim 1 , wherein the downhole tool is a rotary pulser, a rotary steerable motor tool, a vibration damping tool, a measurement-while-drilling tool, or a logging-while-drilling tool, or a downhole measurement tool. 
     
     
         14 . A battery assembly for a downhole tool used in drilling a borehole in an earthen formation, the battery assembly comprising:
 a battery having a first end, a second end opposite to the first end of the battery, and a memory unit integral with the first end of the battery, wherein the memory unit includes stored therein the information related to the battery; and   a module configured to be removably coupled to a battery, the module having:
 a) a chassis; 
 b) a first connector on the chassis, the first connector being configured to couple the module to the battery; 
 c) a processor carried by the chassis, the processor being configured to monitor information related to the battery; 
 d) a communications unit carried by the chassis, the communications unit configured to transmit the information related to the battery at least between the memory unit and the processor when the module is coupled to the first end of the battery and the processor is in electronic communication with the memory unit of the battery; and 
 e) a second connector opposite to the first connector. 
   
     
     
         15 . The battery assembly of  claim 14 , wherein the module includes an elongate element coupled to the chassis. 
     
     
         16 . The battery assembly of  claim 15 , wherein the elongate element is a flexible sleeve that contains wiring. 
     
     
         17 . The battery assembly of  claim 14 , wherein the information related to the battery includes an estimated remaining capacity of the battery. 
     
     
         18 . The battery assembly of  claim 14 , further comprising a current sensor configured to monitor a current draw of the battery over a period of time when the battery module is connected to the battery. 
     
     
         19 . The battery assembly of  claim 14 , further comprising a temperature sensor configured to monitor a temperature of the battery over a period of time when the battery module is connected to the battery. 
     
     
         20 . The battery assembly of  claim 14 , further comprising a voltage sensor configured to monitor a voltage of the battery over a period of time when the battery module is connected to the battery. 
     
     
         21 . The battery assembly of  claim 14 , further comprising an accelerometer configured to monitor at least one of a vibration and shock of the battery over a period of time when the battery module is connected to the battery. 
     
     
         22 . The battery assembly of  claim 14 , further comprising a pressure sensor that is configured to detect a pressure change. 
     
     
         23 . The battery assembly of  claim 14 , wherein the battery is a non-rechargeable battery. 
     
     
         24 . A module configured to be removably coupled to a battery used in a drilling operation that drills a borehole in an earthen formation, the module comprising:
 a chassis;   a first connector on the chassis, the first connector being configured to be removably coupled to the battery;   a processor carried by the chassis, the processor being configured to monitor information related to the battery;   a communications unit carried by the chassis, the communications unit configured to transmit the information related to the battery at least between the memory unit and the processor when the module is coupled to the first end of the battery and the processor is in electronic communication with the memory unit of the battery;   an elongate element coupled to the chassis; and   a second connector coupled to the elongate element opposite to the first connector.   
     
     
         25 . The module of  claim 24 , further comprising an elongate element coupled to the chassis and to second connector. 
     
     
         26 . The module of  claim 24 , further comprising a current sensor configured to monitor a current draw. 
     
     
         27 . The module of  claim 24 , further comprising a temperature sensor configured to monitor a temperature. 
     
     
         28 . The module of  claim 24 , further comprising a voltage sensor configured to monitor a voltage. 
     
     
         29 . The module of  claim 24 , further comprising an accelerometer configured to monitor at least one of a vibration and shock. 
     
     
         30 . A battery system for a downhole tool for use in a drilling operation, the battery system comprising:
 a plurality of battery assemblies, each battery assembly including:
 a) a battery having a first end, a second end opposite to the first, an 
 b) a memory unit carried by the first end of the battery, wherein the memory unit includes stored therein information related to the battery; and 
 c) a processor configured to monitor information related to the battery, and 
 d) a communications unit configured to transmit the information related to the battery at least between the memory unit and the processor; and 
 e) a switch configured to selectively activate the battery; 
   a controller electrically coupled to each switch, wherein the controller is configured to monitor the plurality of battery assemblies and cause each switch to selectively activate the battery.   
     
     
         31 . The battery system of  claim 30 , wherein the plurality of battery assemblies includes a first battery assembly and a second battery assembly,
 wherein the first and second battery assemblies are configured to transition between a deactivated state and an activated state,   wherein the controller is configured to transmit a first signal to the first battery assembly that instructs the first battery assembly to switch to the activated state such that first battery assembly powers the downhole tool.   
     
     
         32 . The battery system of  claim 30 , wherein the plurality of battery assemblies includes a first battery assembly and a second battery assembly,
 wherein the first and second battery assemblies are configured to transition between a deactivated state and an activated state, and the controller is configured to transmit a signal to the first battery assembly and to the second battery assembly that causes the first and second battery assemblies to transition into the activated state, such that the first and second battery assemblies power the downhole tool.   
     
     
         33 . The battery system of  claim 30 , wherein each battery is associated with a battery identifier, wherein the controller is configured to selectively activate the battery based on the battery identifier. 
     
     
         34 . The battery system of  claim 30 , wherein the controller is configured to sequentially activate each battery in the plurality of battery assemblies 
     
     
         35 . The battery system of  claim 30 , wherein each of the plurality of battery assemblies includes a module that is configured to be removably coupled to the battery. 
     
     
         36 . The battery system of  claim 35 , wherein each battery module contains the processor and the communications unit. 
     
     
         37 . The battery system of  claim 30 , wherein each battery includes a pressure sensor that is configured to detect a pressure change. 
     
     
         38 . A method of powering a downhole tool in a drilling operation that forms a borehole in an earthen formation, the method comprising:
 supplying power to the downhole tool with a first battery of a first battery assembly;   determining, via at least one computer processor, a capacity of the first battery of the first battery assembly;   switching the supply of power to the downhole tool from the first battery of the first battery assembly to a second battery of a second battery assembly that is electrically coupled to the first battery assembly when the capacity of the first battery is depleted to a predetermined capacity; and   continuing to supply power to the downhole tool with the second battery of the second battery assembly.   
     
     
         39 . The method of  claim 38 , further comprising transmitting to a surface system an indication that the plurality of battery assemblies have a charge that is less than  25  volts. 
     
     
         40 . The method of  claim 38 , wherein the capacity is a first capacity, and the method further comprises:
 determining, via the at least one processor, a second capacity of the second battery of the second battery assembly;   when the capacity of the second battery is depleted to a predetermined capacity, switching the supply of power to the downhole tool from the second battery of the second battery assembly to a third battery of a third battery assembly that is electronically coupled to one or more of the first battery assembly and the second battery assembly;   continuing to supply power to the downhole tool with the third battery of the second third assembly.   
     
     
         41 . The method of  claim 38 , further comprising:
 transmitting information concerning the first battery assembly and the second battery assembly to a surface of the earthen formation.   
     
     
         42 . The method of  claim 38 , wherein switching the supply of power to the downhole tool from the first battery to the second battery including switching the supply of power with an electronic switch disposed along a circuit that includes the first battery assembly and the second battery assembly. 
     
     
         43 . The method of  claim 38 , wherein switching the supply of power to the downhole tool from the first battery to the second battery occurs automatically when the capacity of the first battery is depleted to the predetermined capacity. 
     
     
         44 . The method of  claim 38 , further comprising:
 assigning a first identifier to the first battery of the first battery assembly;   assigning a second identifier to the second battery of the second battery assembly, wherein the first identifier and the second identifier indicate a relative position of the first battery assembly relative to the second battery assembly, such that power supplied to the downhole tool occurs in sequence based on the respective identifiers.   
     
     
         45 . The method of  claim 26 , further comprising:
 receiving an instruction from the surface of the earthen formation to switch the supply of power to the downhole tool from the first battery to the second battery.   
     
     
         46 . The method of  claim 26 , further comprising:
 monitoring power requirements for one or more other components of the downhole tool; and   when the power requirement of one or more components of the downhole tool exceed a threshold, causing, via a controller, the first and second battery assembly to supply power to the one or more components of the downhole tool.