Elastic Boundary Control in Acoustic Waveguides for High-Fidelity Physical-Layer Telemetry in Downhole Sensor...

In the development of deep shale gas horizontal wells, precise geo-steering relies heavily on downhole sensor networks to acquire extensive formation and engineering parameters. Coiled tubing (CT) provides a promising acoustic waveguide for downhole sensing systems, but conventional acoustic sources rely on gravity-induced interfacial preload. Under highly deviated or horizontal well conditions, the loss of the axial gravity component may induce contact-nonlinearity instability, resulting in waveform distortion and spectral pollution. To address this limitation, a constant-stiffness preloading method based on elastic compliance control is proposed, together with a modal reconstruction strategy achieved by removing high-density tungsten blocks. A fluid-solid coupled dynamic model incorporating contact nonlinearity is established to reveal the dynamic separation mechanism of the acoustic source interface under varying gravity-vector conditions. Wave spring assemblies are then used to reconstruct the mechanical boundary and physically suppress time-domain clipping. Full-scale ground circulation experiments on a 1500 ft CT string show that the proposed method decouples acoustic-source performance from wellbore trajectory. Waveform asymmetry is reduced from 18.4% to 2.1%, and total harmonic distortion decreases from 12.5% to 1.8%. In addition, the first-order longitudinal natural frequency is shifted from 420 Hz to 2850 Hz, avoiding low-frequency pump noise and achieving a 12 dB SNR improvement. This physical-layer gain provides an optimized signal baseline for receiver-end demodulation algorithms. Ultimately, this study provides a robust physical-layer solution for acoustic telemetry in complex deep-earth environments, advancing the reliability of data interaction in downhole sensing systems.