Electric control system of electric workover rig

Abstract

The invention discloses an electric control system of an electric workover rig, which comprises a control module, a driving module, an execution module, a data acquisition module and a monitoring module, and is characterized in that the control module is used for controlling the starting, stopping, up-down moving and rotating actions of the workover rig through a PLC, the driving module comprises a variable-frequency inverter and a bidirectional DC / DC converter, the variable-frequency inverter is used for driving a motor load to operate, and the bidirectional DC / DC converter is used for controlling the motor load to operate. The bidirectional DC / DC converter is used for carrying out charging and discharging management on the energy storage battery, and the execution module is used for completing the control action of the workover rig according to an instruction sent by the control module. According to the invention, the visual monitoring module, the fault detection and alarm module and the multi-modal data fusion analysis module are matched, and real-time data acquisition and image capture are carried out on key parts of the electric control system, so that real-time safety monitoring is carried out on the key parts; and key parts are monitored in real time, and the use condition can be checked at any time, so that the use safety of the electric workover rig is improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of electric workover rigs, in particular to an electric workover rig electric control system. BACKGROUND

[0002] The electric workover rig is usually a workover rig powered by electricity, which can be used for the maintenance, fault handling and deep oil and gas development of oil and water wells, and has the characteristics of high efficiency, energy saving and environmental protection, etc. The electric workover rig usually includes an electric control system.

[0003] The electric control system of the prior art electric workover rig usually includes a programmable logic controller, a human-machine interface, a sensor assembly, an actuator assembly, a communication system and a power supply system, etc. The programmable logic controller as the core of the control system is responsible for collecting sensor data and issuing control instructions to realize the automatic operation of the workover rig. The sensor assembly can monitor the wellhead environmental parameters in real time to ensure the safe operation of the system. The actuator assembly includes electric motors, hydraulic systems and pneumatic systems, which can complete the stretching, rotating and other actions of the drilling rig according to the controller instructions. However, the electric control system is usually not convenient for real-time safety monitoring of key parts such as the motor, gear box, hydraulic valve group, traveling block pulley and drill pipe connection, which may affect the normal use of the electric workover rig. SUMMARY

[0004] The purpose of the present application is to provide an electric workover rig electric control system to solve the problems raised in the background.

[0005] To achieve the above purpose, the present application provides the following technical scheme: an electric workover rig electric control system, comprising an electric control system framework, characterized in that the electric control system framework comprises: a control module, the control module is used to control the start-stop, up-down shifting and rotating action of the workover rig through the PLC; a drive module, the drive module includes a frequency converter and a bidirectional DC / DC converter, the frequency converter is used to drive the motor load to run, and the bidirectional DC / DC converter is used to charge and discharge the energy storage battery; an execution module, the execution module is used to complete the control action of the workover rig according to the instructions issued by the control module; a data acquisition module, the data acquisition module is used to acquire the parameters of the electric control components in real time; a monitoring module, the monitoring module is used to capture the real-time image of the electric control components to monitor the electric control components in real time.

[0006] Preferably, the electric control system framework further comprises: a communication module, the communication module is used for data transmission and communication; A power module for providing, converting and regulating electric energy; A human-machine interaction module for providing an operation interface and data display through a touch screen.

[0007] Preferably, the control module sends control instructions, the driving module and the execution module receive the control instructions and make corresponding control actions, the data acquisition module acquires data of the driving module and the execution module in real time, the monitoring module monitors the operation of the execution module and the driving module, the communication module transmits data, and the data acquired by the data acquisition module is transmitted to the monitoring module through the communication module.

[0008] Preferably, the data acquisition module includes a temperature sensor, a pressure sensor, a current sensor and a vibration sensor, the temperature sensor is used to acquire temperature data of the motor, the frequency converter and other components, the pressure sensor is used to acquire pressure data of the hydraulic system, the current sensor is used to acquire operation data of the motor, and the vibration sensor is used to capture abnormal vibration of mechanical components and acquire abnormal vibration data.

[0009] Preferably, the monitoring module includes: A visual monitoring module for capturing images of the motor, the gear box, the hydraulic valve group, the traveling block pulley and the joint part of the drill pipe in real time, identifying the images, performing behavior analysis and making linkage control; A fault detection and alarm module for setting basic threshold values including temperature, pressure, current and vibration, and comparing with historical operation data, and if an abnormal trend is identified, an alarm is given.

[0010] Preferably, the monitoring module further includes a multi-modal data fusion analysis module for integrating data acquired by the data acquisition module and image results captured by the visual monitoring module, and predicting equipment life and failure risk through a machine learning model.

[0011] Preferably, the data acquisition module transmits the acquired data to the fault detection and alarm module and the multi-modal data fusion analysis module, the fault detection and alarm module compares the data, and if an abnormal trend is detected, an alarm is triggered, at the same time, the visual monitoring module transmits the captured image results to the multi-modal data fusion analysis module, the multi-modal data fusion analysis module integrates the acquired data and the image results to predict equipment life and failure risk.

[0012] Preferably, the visual monitoring module includes: A camera module is used to capture images of the motor, gear box, hydraulic valve group, traveling block pulley and drill pipe connection in real time through a camera layout, the camera layout is that an infrared thermal imaging camera is installed at the motor housing part, the infrared thermal imaging camera is used for image capture and monitoring of temperature anomalies and winding short circuit, a high-definition visible light camera is installed at the gear box part, the high-definition visible light camera is used for image capture and monitoring of gear wear, crack and oil leakage, a macro camera is installed at the hydraulic valve part, the macro camera is used for image capture and monitoring of valve body corrosion and seal ring aging, a dynamic tracking camera is installed at the traveling block pulley part, the dynamic tracking camera is used for image capture and monitoring of steel wire rope deviation and pulley jam, a deep learning auxiliary camera is installed at the drill pipe connection, the deep learning camera is used for image capture and monitoring of thread loosening and connection error; An image recognition module is used for target detection and segmentation of the images captured by the camera module, and outputs results, and the output results include defect type and position and confidence.

[0013] Preferably, the visual monitoring module further comprises: A behavior analysis module is used to detect abnormal vibration of the gear box or jam of the traveling block pulley, and the behavior analysis module uses optical flow method and time sequence analysis for analysis; A linkage control module is used to automatically trigger an alarm and stop the operation of related equipment when a fault is detected, and the linkage control module includes alarm levels, the alarm levels include first-level alarm, second-level alarm and third-level alarm, the first-level alarm is for detecting a serious defect, the second-level alarm is for detecting that the defect development trend is accelerated, and the third-level alarm is for potential risk, and the corresponding response actions of the first-level alarm, second-level alarm and third-level alarm are immediate shutdown and triggering of sound and light alarm, limiting equipment load to fifty percent and generating a maintenance work order, and displaying a warning on the human-computer interaction module and recording to a log.

[0014] Preferably, the camera module transmits the captured images to the image recognition module and the behavior analysis module, the image recognition module and the behavior analysis module identify the images and analyze the behaviors, and generate results, if a fault is identified, an alarm level is generated, the alarm level is transmitted to the linkage control module, and the linkage control module makes a corresponding response action of the alarm level after receiving the alarm level.

[0015] Technical effects and advantages of the present application: The application uses the setting mode of the cooperation of the data acquisition module, the visual monitoring module, the fault detection and alarm module and the multi-modal data fusion analysis module, and through the real-time data acquisition and image capture of the key parts of the electric control system, the real-time safety monitoring of the key parts is carried out, and the key parts are monitored in real time and the use condition can be checked at any time, so as to improve the safety of the electric workover rig. BRIEF DESCRIPTION OF DRAWINGS

[0016] Fig. 1 The application provides an electric control system of an electric workover rig.

[0017] Fig. 2 The application provides an electric control system of an electric workover rig.

[0018] Fig. 3 The application provides an electric control system of an electric workover rig.

[0019] In the figure: 1, electric control system framework; 2, control module; 3, drive module; 4, communication module; 5, execution module; 6, power module; 7, data acquisition module; 8, monitoring module; 801, visual monitoring module; 8011, camera module; 8012, image recognition module; 8013, behavior analysis module; 8014, linkage control module; 802, fault detection and alarm module; 803, multi-modal data fusion analysis module. DETAILED DESCRIPTION

[0020] The technical solutions in the embodiments of the application will be clearly and completely described below with reference to the drawings in the embodiments of the application. Obviously, the described embodiments are only part of the embodiments of the application, rather than all the embodiments of the application. Based on the embodiments in the application, all other embodiments obtained by a person of ordinary skill in the art without creative work fall within the protection scope of the application.

[0021] The application provides an electric control system of an electric workover rig as shown in the figure. Figs. 1-3 The application provides an electric control system of an electric workover rig as shown in the figure.

[0022] Further, the electric control system framework 1 further comprises a communication module 4, a power module 6 and a human-computer interaction module, the communication module 4 is used for transmitting and communicating data, the power module 6 is used for providing electric energy and converting and adjusting the electric energy, and the human-computer interaction module is used for providing an operation interface and data display through a touch screen.

[0023] Further, the data acquisition module 7 comprises a temperature sensor, a pressure sensor, a current sensor and a vibration sensor, the temperature sensor is used for acquiring temperature data of the motor, the frequency converter and other components, the pressure sensor is used for acquiring pressure data of the hydraulic system, the current sensor is used for acquiring operation data of the motor, and the vibration sensor is used for capturing abnormal vibration of mechanical components and acquiring abnormal vibration data.

[0024] Specifically, the monitoring module 8 comprises a visual monitoring module 801 and a fault detection and alarm module 802, the visual monitoring module 802 is used for capturing images of the motor, the gear box, the hydraulic valve group, the traveling block pulley and the drill pipe connection part in real time, and can also visually detect other parts, is not limited to the above parts, and performs image recognition, behavior analysis and linkage control, the fault detection and alarm module 802 is used for setting basic threshold values including temperature, pressure, current and vibration, and comparing with historical operation data, and if an abnormal trend is identified, an alarm is given.

[0025] More specifically, the monitoring module 8 further comprises a multi-modal data fusion analysis module 803 for integrating the data collected by the data collection module 7 and the image results captured by the visual monitoring module 801, and predicting the equipment life and failure risk through a machine learning model, the model prediction adopts an LSTM neural network, the equipment failure prediction model is trained, the feature vectors of normal images and real-time images are extracted by a pre-trained model, the cosine similarity of the two feature vectors is calculated, if the similarity is less than a set value, an alarm is triggered, and the multi-modal data fusion analysis module 803 comprises a hierarchical fusion architecture, the hierarchical fusion architecture comprises a data layer: supporting 100+ sensor nodes access (vibration, temperature, pressure and current, etc.); visual data stream processing: 4-way 4K camera + 1-way infrared thermal imaging; feature layer: time series features: FFT spectrum, wavelet packet energy, Hurst index, spatial features: YOLOv8 detection box, crack length / width measurement; decision layer: cross-modal attention fusion based on Transformer, outputting health index and failure type confidence, and cleaning sensor data, including temperature compensation: establishing a compensation model of thermocouple measurement value and environment temperature; visual data enhancement; dynamic defogging algorithm: for oilfield oil mist environment, using dark channel prior defogging; super-resolution reconstruction: using ESPCN model to improve 320x240 low-resolution thermal imaging to 640x480; then multi-modal feature extraction, time series feature engineering: vibration signal features and current signal features, current signal feature extracts torque-current slope of motor starting current for detecting load abnormalities; visual feature engineering: crack detection features, using Canny operator + Hough transform to extract crack skeleton; calculating crack length (pixels) -> actual length; thermal imaging features: defining temperature anomaly index, the joint decision rule engine of the multi-modal data fusion analysis module 803 can trigger a hydraulic valve leakage alarm if oil leakage is detected by vision and the hydraulic sensor pressure drops by 20%, trigger a gearbox failure alarm and stop if gear crack is detected by vision and vibration sensor acceleration is greater than five, and the confidence weighted involved is visual confidence x 0.6 + sensor confidence x 0.4 -> trigger alarm when the comprehensive decision threshold is greater than or equal to 0.8.

[0026] Further, the visual monitoring module 801 comprises a camera module 8011 and an image recognition module 8012. The camera module 8011 is used to capture images of the motor, gear box, hydraulic valve group, traveling block pulley and drill pipe connection in real time through camera layout. The camera layout is that an infrared thermal imaging camera is installed at the motor housing part, which is used for image capture and monitoring of temperature anomalies and winding short circuit; a high-definition visible light camera is installed at the gear box part, which is used for image capture and monitoring of gear wear, cracks and oil leakage; a macro camera is installed at the hydraulic valve part, which is used for image capture and monitoring of valve body corrosion and seal ring aging; a dynamic tracking camera is installed at the traveling block pulley part, which is used for image capture and monitoring of steel wire rope deviation and pulley jamming; a deep learning auxiliary camera is installed at the drill pipe connection, which is used for image capture and monitoring of thread loosening and connection error. The image recognition module 8012 is used for target detection and segmentation of the images captured by the camera module 8011 and outputs the results, which include defect type and location as well as confidence. The image recognition module 8012 is identified under the action of an edge computing device and uses a YOLOv8-Seg model for image recognition. The input resolution is adjusted to 1280x1280 to adapt to small target detection (such as hydraulic valve seal ring), attention mechanism (CBAM) is introduced to improve the anti-interference ability to complex background (such as oil stains and dust), and training data is increased. 10,000 images of workover rig components are collected, twelve types of defects such as cracks, oil leakage and loosening are labeled, data augmentation (rotation, blur, noise) is used to expand the dataset to 50,000, and then the results are output.

[0027] Further, the visual monitoring module 801 further comprises a behavior analysis module 8013 and a linkage control module 8014, the behavior analysis module 8013 is used for detecting abnormal vibration of the gearbox or the stuck of the car pulley, the behavior analysis module 8013 adopts the optical flow method and the time sequence analysis for analysis, the operation steps of the optical flow method are continuous acquisition of two frames of images, calculation of pixel level displacement field, and then statistics of displacement variance, if the threshold value is exceeded, the vibration alarm is triggered, the operation mode of the time sequence analysis is that ten frames of defect confidence sequences are input, and the future 3 frames of defect development trend (such as crack propagation speed) are output, at the same time, alarm suppression design can be added, anti-shake processing is increased, alarm is triggered only when abnormality is detected for 3 frames in succession, and region filtering is added, non-key regions are ignored, the linkage control module 8014 is used for automatically triggering alarm and stopping the operation of related equipment when fault is detected, emergency braking logic can be adopted for operation, including that the visual detection detects that the offset angle of the car steel wire rope is greater than five degrees, the winch motor power is cut off through the PLC, at the same time, the hydraulic brake is activated, and the event time, position and image snapshot are recorded to the database, the linkage control module 8014 comprises alarm levels, the alarm levels comprise first alarm, second alarm and third alarm, the first alarm is that a serious defect is detected, the second alarm is that the defect development trend is accelerated, and the third alarm is potential risk, and the corresponding response actions of the first alarm, the second alarm and the third alarm are immediate shutdown and triggering of sound and light alarm, limitation of device load to 50% and generation of a maintenance work order and display of a warning on the man-machine interaction module and recording to a log.

[0028] The working principle of the present application is as follows: The control module 2 sends a control instruction, the driving module 3 and the execution module 5 receive the control instruction and make corresponding control actions, at the same time, the data acquisition module 7 collects data of the driving module 3 and the execution module 5 in real time, the monitoring module 8 monitors the operation of the execution module 5 and the driving module 3, the communication module 4 transmits data, and the data collected by the data acquisition module 7 is transmitted to the monitoring module 8 through the communication module 4; The data acquisition module 7 transmits the collected data to the fault detection and alarm module 802 and the multi-modal data fusion analysis module 803, the fault detection and alarm module 802 compares the data, if an abnormal trend is detected, an alarm is triggered, at the same time, the visual monitoring module 801 transmits the captured image result to the multi-modal data fusion analysis module 803, the multi-modal data fusion analysis module 803 integrates the collected data and the image result, and predicts the equipment life and fault risk; The camera module 8011 transmits the captured image to the image recognition module 8012 and the behavior analysis module 8013, the image recognition module 8012 and the behavior analysis module 8013 recognize the image and analyze the behavior, and generate a result, if a fault is recognized, and generate an alarm level, the alarm level is transmitted to the linkage control module 8014, the linkage control module 8014 makes a corresponding response action after receiving the alarm level.

[0029] Finally, it should be noted that: the above only for the preferred embodiments of the present application, and not for the purpose of limiting the present application, although the foregoing detailed description of the present application is made with reference to the foregoing embodiments, for those skilled in the art, it still can be modified, or part of the technical features of the equivalent replacement, within the spirit and principles of the present application, any modification, equivalent replacement, improvement, etc., should be included within the scope of the present application.

Claims

1. An electric control system for an electric workover rig, comprising an electric control system frame (1), characterized in that: The electronic control system framework (1) includes: A control module (2), the control module (2) is used to control the start and stop, up and down movement and rotation of the workover rig through a PLC; A drive module (3), the drive module (3) comprising a variable frequency inverter and a bidirectional DC / DC converter, the variable frequency inverter being used to drive the motor load to operate, and the bidirectional DC / DC converter being used to manage the charge and discharge of the energy storage battery; An execution module (5), the execution module (5) is used to complete the control action of the workover machine according to the instructions issued by the control module (2); A data acquisition module (7), the data acquisition module (7) is used to acquire parameters of the electronic control components in real time; A monitoring module (8) is used to capture real-time images of the electronic control components to monitor the electronic control components in real time.

2. The electric control system for an electric workover rig according to claim 1, characterized in that: The electronic control system framework (1) further includes: A communication module (4), the communication module (4) is used for transmitting data and communicating; A power module (6), the power module (6) is used to provide electric energy and convert and regulate the electric energy; A human-computer interaction module is used to provide an operation interface and data display through a touch screen.

3. The electric control system for an electric workover rig according to claim 1, characterized in that: The control module (2) issues a control instruction, and the driving module (3) and the execution module (5) receive the control instruction and perform corresponding control actions. At the same time, the data acquisition module (7) acquires data from the driving module (3) and the execution module (5) in real time, and the monitoring module (8) monitors the operation of the execution module (5) and the driving module (3). The communication module (4) transmits data, and the data collected by the data acquisition module (7) is transmitted to the monitoring module (8) through the communication module (4).

4. The electric control system for an electric workover rig according to claim 1, characterized in that: The data acquisition module (7) includes a temperature sensor, a pressure sensor, a current sensor and a vibration sensor. The temperature sensor is used to collect temperature data of the motor, the frequency converter and other components. The pressure sensor is used to collect pressure data of the hydraulic system. The current sensor is used to collect operating data of the motor. The vibration sensor is used to capture abnormal vibration of mechanical components and collect abnormal vibration data.

5. The electric control system for an electric workover rig according to claim 1, characterized in that: The monitoring module (8) comprises: A visual monitoring module (801), wherein the visual monitoring module (802) is used to capture images of the motor, gearbox, hydraulic valve group, traveling block pulley and drill pipe connection in real time, and to identify and analyze the images and perform linkage control; The fault detection and alarm module (802) is used to set basic thresholds, including temperature, pressure, current and vibration, and compare them with historical operating data. If an abnormal trend is identified, an alarm is issued.

6. The electric control system for an electric workover rig according to claim 1, characterized in that: The monitoring module (8) further includes a multimodal data fusion analysis module (803), which is used to integrate the data collected by the data acquisition module (7) and the image results captured by the visual monitoring module (801), and predict the equipment life and failure risk through a machine learning model.

7. The electric control system for an electric workover rig according to claim 1, characterized in that: The data acquisition module (7) transmits the collected data to the fault detection and alarm module (802) and the multimodal data fusion analysis module (803). The fault detection and alarm module (802) compares the data and triggers an alarm if an abnormal trend is detected. At the same time, the visual monitoring module (801) transmits the captured image results to the multimodal data fusion analysis module (803). The multimodal data fusion analysis module (803) integrates the collected data and image results to predict the equipment life and failure risk.

8. The electric control system for an electric workover rig according to claim 1, characterized in that: The visual monitoring module (801) comprises: A camera module (8011), the camera module (8011) is used to capture images of the motor, gearbox, hydraulic valve group, traveling block pulley and drill pipe connection in real time through a camera layout, the camera layout is as follows: an infrared thermal imaging camera is installed at the motor housing, the infrared thermal imaging camera is used to capture and monitor temperature anomalies and winding short circuits; a high-definition visible light camera is installed at the gearbox, the high-definition visible light camera is used to capture and monitor gear wear, cracks and oil leakage; a macro camera is installed at the hydraulic valve, the macro camera is used to capture and monitor valve body corrosion and sealing ring aging; a dynamic tracking camera is installed at the traveling block pulley, the dynamic tracking camera is used to capture and monitor wire rope deviation and pulley jamming; a deep learning auxiliary camera is installed at the drill pipe connection, the deep learning camera is used to capture and monitor thread loosening and connection errors; An image recognition module (8012) is used to perform target detection and segmentation on the image captured by the camera module (8011) and output the result, and the output result includes the defect type and location as well as the confidence level.

9. The electric control system for an electric workover rig according to claim 1, characterized in that: The visual monitoring module (801) further comprises: A behavior analysis module (8013), the behavior analysis module (8013) is used to detect abnormal vibration of the gearbox or stuckness of the traveling block pulley, and the behavior analysis module (8013) uses optical flow method and time series analysis for analysis; A linkage control module (8014) is used to automatically trigger an alarm and stop the operation of related equipment when a fault is detected. The linkage control module (8014) includes alarm levels, and the alarm levels include level one alarm, level two alarm, and level three alarm. The level one alarm is for detecting a serious defect, the level two alarm is for detecting an accelerated trend of defect development, and the level three alarm is for potential risks. The response actions corresponding to the level one alarm, level two alarm, and level three alarm are immediate shutdown and triggering of an audible and visual alarm, limiting the equipment load to 50% and generating a maintenance work order, and displaying a warning on the human-computer interaction module and recording it in a log.

10. The electric control system for an electric workover rig according to claim 1, characterized in that: The camera module (8011) transmits the captured image to the image recognition module (8012) and the behavior analysis module (8013). The image recognition module (8012) and the behavior analysis module (8013) recognize the image and analyze the behavior and generate a result. If a fault is recognized and an alarm level is generated, the alarm level is transmitted to the linkage control module (8014). After receiving the alarm level, the linkage control module (8014) performs a response action corresponding to the alarm level.

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