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Autonomous Microsystems for Downhole Applications: Design Challenges, Current State, and Initial Test Results.

Myungjoon Choi1, Yu Sui2, In Hee Lee3

  • 1Center for Wireless Integrated MicroSensing and Systems (WIMS²), University of Michigan, Ann Arbor, MI 48109, USA. myungjun@umich.edu.

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|September 27, 2017
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Summary

Two novel autonomous microsystems, the Michigan Micro Mote for High Temperature (M³HT) and Environmental Logging Microsystem (ELM), are designed for harsh, high-pressure, high-temperature environments. These robust sensing platforms offer wireless data retrieval and extended operational capabilities in extreme conditions.

Keywords:
encapsulationmicrosensorspressuretemperature

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Area of Science:

  • Engineering
  • Materials Science
  • Environmental Monitoring

Background:

  • Harsh industrial environments (high temperature, pressure, corrosive) require robust sensing solutions.
  • Existing microsystems often lack the durability and power for extended deployment in extreme conditions.
  • Autonomous sensing is crucial for real-time data acquisition in challenging settings.

Purpose of the Study:

  • To develop and characterize two autonomous sensing microsystem platforms for deployment in chemically corrosive, high-temperature, and high-pressure environments.
  • To evaluate the performance and durability of these microsystems under extreme operational conditions.
  • To demonstrate wireless data retrieval and system recharging capabilities.

Main Methods:

  • Design and fabrication of the Michigan Micro Mote for High Temperature (M³HT) and Environmental Logging Microsystem (ELM) platforms.
  • Utilized chip-scale batteries and customized electronics for ultralow power consumption in M³HT.
  • Employed off-the-shelf components on flexible PCBs for ELM, incorporating non-volatile memory.
  • Developed specialized encapsulation methods (epoxy-filled volume, stainless-steel shell with sapphire lid) for M³HT and ELM.
  • Tested system performance at temperatures up to 150 °C and pressures up to 10,000 psi in various corrosive media (brine, oil, cement slurry).

Main Results:

  • Both M³HT and ELM platforms demonstrated successful operation and retrieval after deployment in simulated harsh environments.
  • Encapsulation methods effectively protected the microsystems from high pressure and corrosive substances.
  • Wireless communication (RF for M³HT, optical for ELM) enabled post-deployment interrogation and data retrieval.
  • System testing confirmed functionality up to 150 °C and 10,000 psi.
  • Battery life limitations at elevated temperatures restrict active deployment to several hours.

Conclusions:

  • The developed M³HT and ELM platforms are viable autonomous sensing solutions for extreme environments.
  • The encapsulation techniques provide necessary protection for microsystem longevity and data integrity.
  • Further research into high-temperature battery technology is needed to extend active deployment durations.