Ultrasound-based imaging sensor

Abstract

A sensor system, for downhole sensing of a bore hole, includes: a proximal portion comprising: a proximal end of the sensor system that is configured to attach to a downhole tool; a ultrasonic probe that emits ultrasonic signals and receives reflected ultrasonic signals; an electronic circuit with a processor and a memory that collects and stores data from the ultrasonic probe; a first battery that powers the ultrasonic probe and the electronic circuit; and a housing that includes an ultrasonic window; and a distal portion comprising: a detachable joint disposed at a distal end of the sensor system. The proximal portion and the distal portion are arranged in order along a longitudinal axis of the sensor system. The detachable joint has a larger diameter than the housing.

What is claimed is: 
     
         1 . A sensor system for downhole sensing of a bore hole, the sensor system comprising:
 a proximal portion comprising:
 a proximal end of the sensor system that is configured to attach to a downhole tool; 
 a ultrasonic probe that emits ultrasonic signals and receives reflected ultrasonic signals; 
 an electronic circuit with a processor and a memory that collects and stores data from the ultrasonic probe; and 
 a first battery that powers the ultrasonic probe and the electronic circuit; 
 a housing that includes an ultrasonic window; and 
   a distal portion comprising:
 a detachable joint disposed at a distal end of the sensor system; 
   wherein the proximal portion and the distal portion are arranged in order along a longitudinal axis of the sensor system, and   wherein the detachable joint has a larger diameter than the housing.   
     
     
         2 . The sensor system of  claim 1 ,
 wherein the detachable joint includes:
 a tip portion configured to separate from the distal portion of the sensor system to remain in the bore hole; and 
 a base portion that remains with the distal portion of the sensor system. 
   
     
     
         3 . The sensor system of  claim 1 ,
 wherein the detachable joint has the largest diameter of the sensor system.   
     
     
         4 . The sensor system of  claim 1 ,
 wherein the ultrasonic probe is configured to emit ultrasonic waves perpendicularly to the longitudinal axis of the sensor system.   
     
     
         5 . The sensor system of  claim 4 ,
 wherein the ultrasonic probe includes a motor that rotates the ultrasonic probe about the longitudinal axis of the sensor system; and   wherein the motor is connected to and controlled by the electronic circuit.   
     
     
         6 . The sensor system of  claim 5 ,
 wherein the motor is connected to the ultrasonic probe by a shaft that extends through a seal between the ultrasonic probe and the motor.   
     
     
         7 . The sensor system of  claim 1 , further comprising:
 a mirror that reflects the ultrasonic signals,   wherein the ultrasonic probe is configured to face the mirror and is aligned with a central axis of the mirror.   
     
     
         8 . The sensor system of  claim 7 ,
 wherein the ultrasonic probe includes:
 a motor that rotates the mirror about the longitudinal axis of the sensor system; and 
 a second battery that powers the motor, 
   wherein the motor is connected to and controlled by the electronic circuit.   
     
     
         9 . The sensor system of  claim 8 ,
 wherein the motor is connected to the mirror by a shaft that extends through a seal between the mirror and the detachable joint.   
     
     
         10 . The sensor system of  claim 7 ,
 wherein the mirror integrally constitutes the ultrasonic probe.   
     
     
         11 . The sensor system of  claim 10 ,
 wherein the ultrasonic probe includes a motor that rotates the ultrasonic probe about the longitudinal axis of the sensor system, and   wherein the motor is connected to and controlled by the electronic circuit.   
     
     
         12 . The sensor system of  claim 1 ,
 wherein the housing comprises a plastic, a super engineered plastic, a glass, a ceramic, a glass fiber reinforced plastic (GFRP), a carbon fiber reinforced plastic (CFRP), or a metal.   
     
     
         13 . The sensor system of  claim 1 ,
 wherein the electronic circuit includes a localization sensor that determines position information of the sensor system within the bore hole.   
     
     
         14 . A sensor system for downhole sensing of a bore hole, the sensor system comprising:
 a proximal portion comprising:
 a proximal end of the sensor system that is configured to attach to a downhole tool; 
 a ultrasonic probe that emits ultrasonic signals and receives reflected ultrasonic signals; 
 an electronic circuit with a processor and a memory that collects and stores data from the ultrasonic probe; and 
 a first battery that powers the ultrasonic probe and the electronic circuit; 
 a housing that includes an ultrasonic window; 
   a base portion disposed at a distal end of the sensor system; and   a centralizer with a larger diameter than the housing,   wherein the centralizer is configured to position the sensor system at a centered position within a casing of the bore hole.   
     
     
         15 . The sensor system of  claim 14 ,
 wherein the sensor system includes at least two centralizers disposed on opposite ends of the housing.   
     
     
         16 . The sensor system of  claim 15 ,
 wherein the at least two centralizers include:
 a first centralizer attached to the base portion; and 
 a second centralizer attached as the proximal end of the sensor system and is configured to attach to the downhole tool. 
   
     
     
         17 . The sensor system of  claim 15 ,
 wherein the at least two centralizers are independently adjustable.   
     
     
         18 . The sensor system of  claim 1 ,
 wherein the ultrasonic probe is configured to emit ultrasonic waves perpendicularly to the longitudinal axis of the sensor system.   
     
     
         19 . The sensor system of  claim 4 ,
 wherein the ultrasonic probe includes a motor that rotates the ultrasonic probe about the longitudinal axis of the sensor system; and   wherein the motor is connected to and controlled by the electronic circuit.