Controlled-rotation test bench for a downhole device

• IndustryOil & Gas, completion tools
• DisciplineMechatronics, mechanical design and control
• Specification0.3 g tangential · 3.8 g centrifugal · Ø 260 mm
• DeliverableComplete bench, HMI, manual, FAT and SAT protocols

The challenge

Evaluating a downhole device's response to a defined acceleration profile: a ramp with controlled tangential acceleration followed by constant speed to hold a target centrifugal acceleration. The bench must be repeatable, safe and operable by the client's staff without our intervention.

Scope

• Mechanical design of the bench: industrial frame, device mounting shaft and moving-part guarding
• Servo motor with bevel gearbox, closed-loop speed control with resolver feedback
• Electrical panel with protections, interlocked disconnect, local push-buttons and local/remote selector
• PC-based HMI: setpoint, parametric ramps, multi-stage profiles, variable supervision and alarms
• Acquisition and download of the speed and acceleration curves of each test
• Functional safety: emergency stop, guard interlocks, LOTO and status signalling
• Component procurement, fabrication and factory testing with the client's actual part
• Remote commissioning and training, operating manual and FAT/SAT protocols

How we worked

From test profile to drive specification. Target accelerations were translated into ramp, final speed and required torque, and from there into servo, gearbox and drive selection.

Control built to grow. Architecture ready to integrate accelerometers and automatic reports without structural changes to the control.

Turnkey. Design, procurement, fabrication, FAT, shipping, remote SAT and training under a single contract.