Wireless monitoring system

Abstract

The invention discloses a wireless monitoring system which comprises a multi-parameter wireless sensing terminal, an anti-interference wireless transmission link, an intelligent host receiving system and an emergency backup module. The multi-parameter wireless sensing terminal collects and sends various types of equipment and environment parameters, the anti-interference wireless transmission link guarantees transmission through time division multiple access and the like, the intelligent host receiving system receives and analyzes data, predicts the parameter trend and links an external system, and the emergency backup module caches or takes over the data when a host is abnormal. According to the invention, the limitation of single parameter monitoring is broken through, and multi-dimensional equipment health monitoring is realized; the data transmission stability and integrity are ensured; equipment faults are early warned in advance, and an external system is linked for rapid handling; the endurance of the multi-parameter wireless sensing terminal is prolonged, the long-term operation requirement is met, and the problem of multiple pain points in the prior art is solved.

Description

Technical Field

[0001] This invention belongs to the field of oil and gas extraction equipment monitoring technology, and relates to a wireless monitoring system. Background Technology

[0002] In the field of oil and gas extraction, fracturing is a core and critical process for improving the productivity of oil and gas wells. Its operational efficiency and equipment safety directly determine extraction costs and production benefits. With the continuous upgrading of fracturing technology, in order to ensure the safety of on-site personnel and avoid personal risks in high-pressure working environments, the industry now generally adopts the remote control mode of instrument trucks for fracturing operations. That is, the start-up, shutdown, and parameter adjustment of all fracturing pumps are completed through the control system in the instrument truck. The area around the fracturing truck is designated as a high-risk working area, and personnel are strictly prohibited from entering the site.

[0003] However, while this remote control mode solves the problem of personnel safety, it also introduces significant blind spots in equipment status monitoring. The specific technical defects and hazards are as follows: As the core power equipment in fracturing operations, the lubrication system of the fracturing pump is a key component ensuring stable operation. The lubricating oil pressure must be maintained within a specific threshold range to effectively lubricate and cool moving parts such as gears and bearings on the power end, preventing wear or overheating due to frictional heat. However, in the current operating mode, personnel cannot access the fracturing truck site to obtain real-time lubricating oil pressure data through traditional on-site instruments or manual testing. When the lubricating oil pressure falls below the threshold due to pipeline leaks, pump malfunctions, or other reasons, the control system inside the instrument truck cannot detect it in time, leading to lubrication failure on the power end and a sharp rise in pump head temperature. If this abnormal state persists, it can cause fracturing operations to be interrupted and require shutdown for maintenance; in severe cases, it can lead to irreversible damage to the core components of the pump head, resulting in high equipment maintenance costs, significantly extended operating cycles, and serious economic losses.

[0004] Furthermore, the fracturing operation site environment is complex. During high-load operation, critical components of fracturing pumps and power systems (such as engines and hydraulic systems), including motor windings, hydraulic pipeline interfaces, and fuel supply components, are prone to abnormally high temperatures due to overload, short circuits, and seal failures. If these issues are not detected and addressed promptly, they can easily lead to fires. While conventional fire-fighting equipment is available at fracturing sites, there is a lack of real-time temperature monitoring mechanisms for these critical components. On the one hand, personnel cannot directly inspect the equipment on-site, making it impossible to detect early signs of problems such as component overheating and leaks. On the other hand, traditional temperature monitoring methods (such as fixed wired temperature sensors) are limited by the harsh environment of fracturing sites, including high pressure, vibration, and oil contamination, leading to issues such as line damage and signal interruptions, making stable real-time monitoring difficult. This results in most fracturing site fires going undetected in their early stages, often only being discovered when they reach the open flame stage. At this point, not only is firefighting significantly more difficult, but it can also cause serious consequences such as equipment damage, expanded pollution of the work area, and even threaten the safety of surrounding personnel and facilities.

[0005] In summary, the existing remote control model for fracturing operations lacks a technical solution capable of overcoming on-site personnel access restrictions and enabling real-time monitoring of key equipment parameters. The industry urgently needs a monitoring device that can wirelessly transmit data from secure areas such as conference rooms and duty rooms at fracturing well sites to obtain real-time information on fracturing pump power end lubricating oil pressure, temperature of key equipment components, and power system operating status. This would fill existing monitoring blind spots, provide early warnings of equipment anomalies, nip potential accidents in the bud, and provide strong support for the safe and efficient conduct of fracturing operations, thus solving the current equipment safety monitoring challenges facing the industry. Summary of the Invention

[0006] To address the problems existing in the background technology, this invention proposes a wireless monitoring system, which aims to solve the problem that the existing technology cannot meet the monitoring requirements of fracturing well sites for the real-time performance, stability, ease of maintenance, low power consumption, and complete data of key equipment of fracturing trucks.

[0007] The first aspect of this application provides a wireless monitoring system, including: a multi-parameter wireless sensing terminal, an anti-interference wireless transmission link, an intelligent host receiving system, and an emergency backup module; The multi-parameter wireless sensing terminal is used to collect data from fracturing operations and transmit the data through the anti-interference wireless transmission link. The anti-interference wireless transmission link is used to transmit data to the intelligent host receiving system; The intelligent host receiving system is used to receive, parse, and store the data, provide alerts for abnormal data conditions, allocate dedicated transmission time slots to each multi-parameter wireless sensing terminal, and set emergency time slots so that faulty multi-parameter wireless sensing terminals can transmit data first. Based on historical data, it predicts the trend of equipment operating parameters, identifies equipment fault types and generates maintenance suggestions, and establishes connections with the remote control system of the instrument vehicle for fracturing operations, the well site fire protection system, and the equipment management cloud platform to achieve data interaction and collaborative control. The emergency backup module is used to cache data or take over reception when the intelligent host receives a system malfunction.

[0008] Optionally, the multi-parameter wireless sensing terminal includes a sensing unit, a signal processing unit, a wireless transmission unit, a power supply unit, and a fault self-testing unit; The sensing unit is connected to the signal processing unit and is used to collect data and send the signals obtained from the collected data to the signal processing unit. The signal processing unit is connected to the wireless transmission unit and the fault self-test unit, respectively, and is used to convert the signals sent by the sensing unit into digital signals, perform self-tests on the multi-parameter wireless sensing terminal, generate data frames with unique identifiers, and adjust the acquisition frequency of the device operating parameters according to the instructions received by the intelligent host system. The wireless transmission unit is used to send the data frames generated by the signal processing unit through an anti-interference wireless transmission link. The power supply unit is connected to the sensing unit, signal processing unit, wireless transmission unit, and fault self-test unit, respectively, and is used to supply power. The fault self-test unit is used to detect the status of the sensing unit and the power supply unit and generate device status codes and fault codes.

[0009] Optionally, the sensing unit includes a pressure sensor, a temperature sensor, a vibration sensor, an oil level sensor, a temperature and humidity sensor, and a dust concentration sensor; The pressure sensor is used to collect the pressure of the lubricating oil at the power end of the fracturing truck and fracturing pump; the temperature sensor is used to collect the temperature of the lubricating oil at the power end of the fracturing pump and the temperature of the power system of the fracturing truck; the vibration sensor is used to collect the vibration frequency at the power end of the fracturing pump; the oil level sensor is used to collect the oil level of the lubricating oil at the power end of the fracturing pump; the temperature and humidity sensor is used to collect the ambient temperature and humidity of the fracturing well site; and the dust concentration sensor is used to collect the dust concentration at the fracturing well site. The data frame generated by the signal processing unit includes a frame header, address code, fault code, device status code, and check bit; wherein, the frame header is the system operating frequency band identifier, and the address code is the unique identifier of the multi-parameter wireless sensing terminal.

[0010] Optionally, the power supply unit includes a battery and a battery management circuit; the battery management circuit is used to provide overcharge protection and over-discharge protection for the battery and to calculate the battery's health status in real time; the fault codes generated by the fault self-test unit include sensor fault codes and low battery fault codes.

[0011] Optionally, the anti-interference wireless transmission link employs frequency division multiplexing and code division multiplexing; the frequency division multiplexing allocates a unique operating frequency band to each target monitoring system; the code division multiplexing allocates a unique address code to each multi-parameter wireless sensing terminal; and the intelligent host receiving system only receives data that matches the operating frequency band and address code.

[0012] Optionally, the intelligent host receiving system includes hardware and software components; The hardware component includes an industrial all-in-one computer, a wireless transmission and receiving module, an external antenna, an audible and visual alarm module, an edge computing module, and an industrial bus communication interface. The wireless transmission and receiving module is connected to the industrial all-in-one computer to receive and transmit data. The external antenna is connected to the wireless transmission and receiving module to enhance signal reception. The audible and visual alarm module is connected to the industrial all-in-one computer to issue alerts when data is abnormal. The edge computing module is connected to the industrial all-in-one computer for local data processing. The industrial bus communication interface is connected to the industrial all-in-one computer to enable data interaction between the intelligent host receiving system and external devices. The software component is used to display data in real time, identify and alert on faults, set alarm thresholds, manage historical data, export and print data, manage equipment, predict equipment operating parameter trends based on historical data, identify equipment fault types, and generate maintenance suggestions.

[0013] Optionally, the alarm notification function of the software part divides the alarm levels into early warning, level one alarm, level two alarm, and emergency alarm; in the early warning state, a pop-up notification is only displayed on the software interface of the industrial computer all-in-one machine; in the level one alarm state, an audible and visual alarm is triggered and an early warning information is pushed to the on-duty personnel's mobile application; in the level two alarm state, an audible and visual alarm is triggered, an alarm information is pushed to the on-duty personnel's mobile application, and a maintenance work order is automatically generated; in the emergency alarm state, an audible and visual alarm is triggered, an alarm information is pushed to the on-duty personnel's mobile application, a maintenance work order is automatically generated, and a linkage command is sent to the well site emergency command center; the historical data management function of the software part includes storing data by timestamp, querying data by vehicle number and time range, and generating historical curves.

[0014] Optionally, the emergency backup module includes a data caching mechanism. This mechanism automatically enters a low-power caching mode when the multi-parameter wireless sensing terminal fails to receive a response signal from the intelligent host receiving system for a preset number of consecutive cycles. It caches data and extends the data transmission interval. When the intelligent host receiving system recovers, the multi-parameter wireless sensing terminal retransmits the cached data to the intelligent host receiving system and restores the original data transmission interval. When the multi-parameter wireless sensing terminal enters the low-power caching mode, it reduces the operating current of the microcontroller unit and disables unnecessary functions of the wireless transmission unit. The data caching employs a cyclic overwrite mechanism, overwriting only the oldest stored data.

[0015] Optionally, the emergency backup module includes a backup intelligent host; the backup intelligent host pre-stores the operating frequency band information and address code pairing list of each target monitoring system. When the intelligent host receiving system is damaged, the backup intelligent host automatically scans the address codes of multi-parameter wireless sensor terminals in the current operating frequency band after powering on, completes pairing, and receives data; when the target monitoring system is deployed at the well site, each intelligent host receiving system forms a distributed monitoring network through networking. When a certain intelligent host receiving system fails, the surrounding intelligent host receiving systems automatically share its data storage and alarm functions.

[0016] Optionally, the data collected by the multi-parameter wireless sensing terminal includes: the pressure and temperature of the lubricating oil at the power end of the fracturing truck and fracturing pump, the temperature of the power system of the fracturing truck, the vibration frequency of the power end of the fracturing pump, the oil level of the lubricating oil at the power end of the fracturing pump, the pressure of the hydraulic system of the fracturing pump, the ambient temperature and humidity of the fracturing well site, and the dust concentration of the fracturing well site.

[0017] Compared with the prior art, the present invention has the following beneficial effects: This invention provides a wireless monitoring system, comprising: a multi-parameter wireless sensing terminal, an anti-interference wireless transmission link, an intelligent host receiving system, and an emergency backup module. The multi-parameter wireless sensing terminal collects and transmits various device and environmental parameters. The anti-interference wireless transmission link utilizes time-division multiple access (TDMA) and other methods to ensure transmission. The intelligent host receiving system receives and analyzes the data, predicts parameter trends, and coordinates with external systems. In the event of host failure, the emergency backup module triggers an emergency caching mechanism to cache or take over the data. This invention overcomes the limitations of single-parameter monitoring, achieving multi-dimensional device health monitoring; ensuring stable and complete data transmission; providing early warning of device failures and enabling rapid response from external systems; extending the battery life of the multi-parameter wireless sensing terminal to meet long-term operational needs, and addressing many pain points of existing technologies. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of a wireless monitoring system according to an embodiment of the present invention. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] In one embodiment, such as Figure 1 As shown, a wireless monitoring system is provided, which includes: a multi-parameter wireless sensor terminal, an anti-interference wireless transmission link, an intelligent host receiving system, and an emergency backup module. Detailed descriptions of each functional module are as follows: The multi-parameter wireless sensing terminal is used to collect data and transmit the collected data through the anti-interference wireless transmission link. The data collected by the multi-parameter wireless sensing terminal includes: the pressure and temperature of the lubricating oil at the power end of the fracturing truck and fracturing pump, the temperature of the fracturing truck's power system, the vibration frequency of the fracturing pump's power end, the oil level of the lubricating oil at the power end of the fracturing pump, the pressure of the fracturing pump's hydraulic system, the ambient temperature and humidity of the fracturing well site, and the dust concentration at the fracturing well site. The wireless monitoring system described in this application is used when a fracturing pump is installed on the fracturing truck.

[0021] The anti-interference wireless transmission link is used to transmit data sent by the multi-parameter wireless sensing terminal to the intelligent host receiving system. Specifically, the anti-interference wireless transmission link is a data relay device used to receive data sent by the multi-parameter wireless sensing terminal and transmit the data to the intelligent host receiving system.

[0022] The intelligent host receiving system is used to receive, parse, and store the data, provide alerts for data anomalies, allocate dedicated transmission time slots to each multi-parameter wireless sensor terminal, and set emergency time slots to prioritize data transmission from faulty multi-parameter wireless sensor terminals. It predicts equipment operating parameter trends based on historical data, identifies equipment fault types, generates maintenance suggestions, and establishes connections with the remote control system of the fracturing operation instrument vehicle, the well site fire protection system, and the equipment management cloud platform to achieve data interaction and collaborative control. The emergency backup module is used to cache or take over data reception when the intelligent host receiving system malfunctions.

[0023] The equipment management cloud platform boasts multi-dimensional functions: First, data storage and traceability. It stores fracturing truck operating parameters, environmental parameters, and alarm records categorized by timestamp and equipment number, supporting cross-well site and cross-time period data queries and historical curve generation, providing data support for the entire equipment lifecycle management. Second, global equipment status monitoring. It displays the real-time operating status of all fracturing trucks connected to the system, including status indicators such as normal operation, early warning, and alarm. The platform allows users to view the distribution of equipment and real-time data at each well site via map positioning. Third, collaborative maintenance work orders. The intelligent host receives maintenance work orders corresponding to level 2 and above alarms sent by the system, automatically assigns them to regional maintenance teams, tracks work order processing progress (e.g., accepted, under maintenance, completed), and associates maintenance records with historical equipment faults to form a closed-loop maintenance system. Fourth, data analysis and report generation. It performs cross-equipment comparative analysis based on massive historical data. For example, it tracks parameter differences and fault mode statistics for the same model of fracturing truck; and common fault types and their frequency, automatically generating monthly / quarterly equipment operation reports to provide decision-making basis for optimizing equipment maintenance strategies. Fifth, system configuration management supports remote adjustment of parameters such as alarm thresholds and data acquisition frequency of the intelligent host, and synchronous updates to all associated multi-parameter wireless sensing terminals, realizing unified control of global system configuration.

[0024] The intelligent host receiving system centrally manages time slot allocation, enabling orderly and interference-resistant data transmission from multi-parameter wireless sensor terminals in the target monitoring system. This target monitoring system is a complete monitoring system independently deployed for a single fracturing well site or specific operational area. The wireless monitoring system described in this application is networked to form the target monitoring system. The specific process is as follows: During the initialization of the intelligent host receiving system, the 1-second transmission cycle is divided into N equal-length basic time slots based on the number of multi-parameter wireless sensor terminals deployed at the well site, where N-1 is the total number of multi-parameter wireless sensor terminals. For example, with 9 multi-parameter wireless sensor terminals, each terminal is allocated a dedicated 100ms time slot. Multi-parameter wireless sensor terminal 1 corresponds to 0-100ms, multi-parameter wireless sensor terminal 2 corresponds to 100-200ms, and so on. At the same time, 100ms is reserved at the end of each cycle as an emergency time slot.

[0025] The intelligent host receiving system sends time slot allocation instructions to all multi-parameter wireless sensing terminals through an anti-interference wireless transmission link, specifying the start and end times, period, and emergency triggering conditions of the time slots for each multi-parameter wireless sensing terminal. After receiving the instructions, the microcontroller unit of each multi-parameter wireless sensing terminal records and strictly follows the time slot rules.

[0026] To ensure time slot synchronization, the intelligent host receiving system sends a time slot calibration command once every preset time period, carrying the intelligent host receiving system's time. The multi-parameter wireless sensing terminal receives this command and automatically calibrates its internal clock to avoid time slot overlap due to clock offset. If a new multi-parameter wireless sensing terminal is added, the intelligent host receiving system immediately recalculates the basic time slot duration after detecting a pairing signal. For example, when increasing from 9 to 10 terminals, each time slot is adjusted to 90.9ms. A time slot update command is then pushed to all multi-parameter wireless sensing terminals to achieve dynamic adaptation.

[0027] When a multi-parameter wireless sensor terminal detects that a parameter exceeds the emergency threshold, a sensor malfunctions, or the battery is low, it automatically sends an emergency transmission request to the intelligent host receiving system. The intelligent host receiving system prioritizes the requests according to fire risk > equipment malfunction > low battery, authorizing the multi-parameter wireless sensor terminal to transmit first within the emergency time slot. After transmission is completed, the authorization is released. If multiple multi-parameter wireless sensor terminals request the request simultaneously, they will occupy the emergency time slot sequentially to avoid channel congestion.

[0028] To address time slot conflicts and data loss, the intelligent host receiving system monitors the transmission status of multi-parameter wireless sensing terminals in real time. If a multi-parameter wireless sensing terminal fails to transmit within its designated time slot (e.g., due to signal obstruction), it is immediately marked as a time slot-abnormal multi-parameter wireless sensing terminal, and a retransmission time slot of equal duration is allocated in the next cycle. After detecting its own abnormality, the multi-parameter wireless sensing terminal temporarily stores its data and completes transmission within the retransmission time slot. If three consecutive transmission failures occur, the intelligent host receiving system triggers an emergency buffering mechanism, and the multi-parameter wireless sensing terminal enters a low-power mode to buffer data. Once the signal is restored, the data is completed via a retransmission command, ensuring the integrity and timeliness of data transmission in complex well site environments.

[0029] The microcontroller unit in this application is the core control component of the multi-parameter wireless sensing terminal, undertaking the coordination and management functions of the overall operation of the multi-parameter wireless sensing terminal. It receives instructions from the signal processing unit, controls the sensing units to collect various parameters at a set frequency; manages the activation and deactivation of the wireless transmission unit and the timing of data transmission, ensuring data transmission is completed within the dedicated time slot allocated by the anti-interference wireless transmission link; monitors the battery status of the power supply unit, and, in conjunction with data from the battery management circuit, regulates the power consumption of the multi-parameter wireless sensing terminal, reducing its own operating current and shutting down unnecessary modules in low-power buffer mode; receives status information from the fault self-test unit, and triggers corresponding processing mechanisms when an anomaly is detected, such as initiating an emergency time slot transmission request. Through centralized control of each unit, the microcontroller unit ensures the coordinated operation of all functional modules of the multi-parameter wireless sensing terminal, achieving integrated data acquisition, processing, transmission, and status management.

[0030] In this embodiment, the multi-parameter wireless sensing terminal includes a sensing unit, a signal processing unit, a wireless transmission unit, a power supply unit, and a fault self-testing unit. The sensing unit is connected to the signal processing unit and is used to collect data and send the signals obtained from the collected data to the signal processing unit. The signal processing unit is connected to both the wireless transmission unit and the fault self-testing unit, and is used to convert the signals sent by the sensing unit into digital signals, perform self-testing on the multi-parameter wireless sensing terminal, generate data frames with unique identifiers, and adjust the acquisition frequency of device operating parameters according to the instructions received by the intelligent host system. The wireless transmission unit is used to send the data frames generated by the signal processing unit through an anti-interference wireless transmission link. The power supply unit is connected to both the sensing unit, the signal processing unit, the wireless transmission unit, and the fault self-testing unit and is used to supply power. The fault self-testing unit is used to detect the status of the sensing unit and the power supply unit and generate device status codes and fault codes. The device status code is a standardized code used to describe the real-time operating status of the multi-parameter wireless sensing terminal and the monitored fracturing equipment components. It covers both the terminal's own status and the status of its components. The real-time operating status of the monitored fracturing equipment components includes: battery status, sensor status, communication status, environmental status, etc. The device status code includes various values ​​acquired by the sensing unit. The fault code is a standardized code used to accurately identify the specific fault type, location, and severity of the multi-parameter wireless sensing terminal. It mainly targets abnormal events that exceed the normal operating range, facilitating rapid problem location and triggering corresponding handling procedures.

[0031] The sensing unit includes a pressure sensor, a temperature sensor, a vibration sensor, an oil level sensor, a temperature and humidity sensor, and a dust concentration sensor. The pressure sensor is used to collect the pressure of the lubricating oil at the power end of the fracturing truck and the fracturing pump. The temperature sensor is used to collect the temperature of the lubricating oil at the power end of the fracturing pump and the temperature of the power system of the fracturing truck. The vibration sensor is used to collect the vibration frequency at the power end of the fracturing pump. The oil level sensor is used to collect the oil level of the lubricating oil at the power end of the fracturing pump. The temperature and humidity sensor is used to collect the ambient temperature and humidity of the fracturing well site. The dust concentration sensor is used to collect the dust concentration at the fracturing well site. The data frame generated by the signal processing unit includes a frame header, an address code, a fault code, an equipment status code, and a check bit. The frame header is the system operating frequency band identifier, and the address code is the unique identifier of the multi-parameter wireless sensing terminal.

[0032] The power supply unit includes a battery and a battery management circuit. The battery management circuit provides overcharge and over-discharge protection for the battery and calculates the battery's health in real time. The fault codes generated by the fault self-test unit include sensor fault codes and low battery fault codes.

[0033] In this embodiment, the anti-interference wireless transmission link employs frequency division multiplexing (FDM) and code division multiplexing (CDM). FDM allocates a unique operating frequency band to each target monitoring system; CDM allocates a unique address code to each multi-parameter wireless sensing terminal; the intelligent host receiving system only receives data matching the operating frequency band and address code. Specifically, the FDM operating frequency band ranges from 433.1 to 433.9 MHz, with adjacent operating frequency bands spaced 0.1 MHz apart; the CDM address code is 16 bits, with a value range of 0001-FFFF.

[0034] The signal transmission area of ​​the shell of the multi-parameter wireless sensing terminal is embedded with high-frequency transparent ceramic material, and the antenna inside the multi-parameter wireless sensing terminal is set close to the signal transmission area of ​​the shell.

[0035] In this embodiment, the intelligent host receiving system includes hardware and software components. The hardware component includes an industrial all-in-one computer, a wireless transmission and receiving module, an external antenna, an audible and visual alarm module, an edge computing module, and an industrial bus communication interface. The wireless transmission and receiving module is connected to the industrial all-in-one computer and is used to receive data sent by multi-parameter wireless sensing terminals and transmit it to the industrial all-in-one computer. The external antenna is connected to the wireless transmission and receiving module to enhance signal reception strength. The audible and visual alarm module is connected to the industrial all-in-one computer and is used to issue alerts when data is abnormal. The edge computing module is connected to the industrial all-in-one computer and is used to perform local processing on the collected data. The industrial bus communication interface is connected to the industrial all-in-one computer and is used to enable data interaction between the intelligent host receiving system and external devices. The software component is used for real-time data display, fault identification and alerting, setting alarm thresholds, managing historical data, exporting and printing data, managing equipment, predicting equipment operating parameter trends based on historical data, identifying equipment fault types, and generating maintenance suggestions.

[0036] The alarm notification function of the software categorizes alarm levels into early warning, level one alarm, level two alarm, and emergency alarm. In early warning mode, a pop-up notification only appears on the intelligent host software interface; in level one alarm mode, an audible and visual alarm is triggered, and an early warning message is pushed to the on-duty personnel's mobile application; in level two alarm mode, an audible and visual alarm is triggered, an early warning message is pushed to the on-duty personnel's mobile application, and a maintenance work order is automatically generated; in emergency alarm mode, an audible and visual alarm is triggered, an early warning message is pushed to the on-duty personnel's mobile application, a maintenance work order is automatically generated, and a linkage command is sent to the well site emergency command center. The historical data management function of the software includes storing data by timestamp, querying data by vehicle number and time range, and generating historical curves. The equipment management function of the software includes editing channel names and automatically identifying and pairing when a new multi-parameter wireless sensor terminal or industrial computer is replaced.

[0037] The early warning phase utilizes multi-dimensional data collection and machine learning prediction to proactively identify equipment risks. The specific process is as follows: The multi-parameter wireless sensing terminal constructs a three-dimensional data pool of equipment, environment, and status. Core equipment operating parameters include the lubricating oil pressure of the fracturing truck and fracturing pump power end, the lubricating oil temperature of the fracturing pump power end, the temperature of the fracturing truck power system, and the vibration frequency of the fracturing pump power end. Real-time values ​​and extreme values ​​and average values ​​within one minute are recorded for each parameter. Environmental parameters cover the well site environment's temperature, relative humidity, and inhalable dust concentration, with average values ​​recorded every 5 seconds. The multi-parameter wireless sensing terminal's own status parameters are generated as sensor equipment status codes by a fault self-checking unit. These data are encapsulated into data frames by a signal processing unit in a fixed format, such as frame header + address code + fault code + equipment status code + check bit, and then transmitted in real-time to the intelligent host receiving system by the wireless transmission unit.

[0038] The edge computing module of the intelligent host receiving system performs three layers of preprocessing on the data: First, it verifies data integrity using a checksum, removes invalid data, and replaces equipment parameters exceeding the normal range with the average of the last five data points. For environmental parameters, it uses a moving average method to process instantaneous peak values. The average replacement refers to the five successfully acquired and verified data points immediately preceding the current abnormal data point in the time series. Assuming the current time is T, if the lubricating oil pressure data acquired at time T is abnormal, the intelligent host receiving system will trace back to the lubricating oil pressure data acquired and verified at times T-1, T-2, T-3, T-4, and T-5, calculate their average, and use this as the replacement value for the abnormal data at time T. The purpose of this is to utilize the continuity and correlation of equipment operation data to, to some extent, eliminate the impact of abnormal data caused by accidental factors on the overall data analysis, ensuring data stability and reliability, and providing more valuable information for subsequent data-driven prediction and early warning operations. Second, it establishes a correlation model between environmental and equipment parameters. For example, the normal threshold for lubricating oil pressure is lowered by 3% for every 10°C increase in ambient temperature. Simultaneously, data from similar sensors are cross-validated, and the average value is taken and marked when the deviation exceeds 3°C. Finally, time features, trend features, and correlation features are extracted and converted into feature vectors for storage.

[0039] The preprocessed data is input into the built-in lightweight LSTM time-series prediction model. The LSTM model is initially trained using three months of normal operation data and 50 fault cases, and is updated incrementally with new data within each preset period. The edge computing module inputs the latest feature vectors into the model within each preset time period, outputting parameter prediction curves and risk probabilities for the next 12-24 hours. For example, it predicts that the lubricating oil pressure will drop from 0.32 MPa to 0.29 MPa after 20 hours, with a risk probability of 65%. Simultaneously, it calculates the parameter change rate threshold; if the hourly decrease exceeds 0.05 MPa, the risk probability increases by 20%. The model also compares with a historical fault case database. If the feature similarity is above 80%, it outputs the possible fault type. If the consecutive prediction deviation exceeds 10%, it automatically performs a second prediction. The automatic second prediction means that if the deviation between two consecutive parameter predictions exceeds 10%, the prediction model triggers a second prediction mechanism, recalculates, and outputs a corrected prediction result.

[0040] Ultimately, the software determines the warning based on the prediction results and real-time parameters. A warning is triggered when the model predicts that the parameter will enter the warning threshold boundary within 12-24 hours with a risk probability ≥60%, or when the real-time parameter is normal but shows a monotonic trend in three consecutive predictions, or when environmental changes will cause the parameter to enter the warning threshold. The warning information is displayed on the interface as a flashing yellow icon and text prompt, a non-mandatory pop-up window containing the prediction curve, risk type, and suggested actions appears, and the warning is stored in a fixed format in the warning log, supporting historical queries.

[0041] In this embodiment, the grading process is based on the parameter threshold system preset by the intelligent host receiving system, combined with multi-dimensional data to achieve accurate grading, specifically as follows: The software sets three threshold levels for each type of monitoring parameter, including: normal threshold range, such as lubricating oil pressure 0.3-0.5MPa; alarm threshold boundary, such as 0.25-0.3MPa or 0.5-0.55MPa; and emergency threshold boundary, such as <0.2MPa or >0.6MPa, and supports adjustment according to equipment model and operating conditions. The data frames transmitted by the multi-parameter wireless sensing terminal must include the real-time parameter value, rate of change, and equipment status code, providing three-dimensional support for grading: static values, dynamic trends, and equipment status.

[0042] The logic for determining a Level 4 alarm is as follows: A warning is triggered when the parameter is at the warning threshold boundary and the rate of change is ≤0.05 MPa / hour, or when a minor problem equipment status code is received and the core parameters are normal, or when the model predicts that the parameter may exceed the limit in 12-24 hours. A Level 1 alarm corresponds to a parameter within the alarm threshold boundary but with a rate of change >0.05 MPa / hour, or when a moderate problem equipment status code is received and cross-verification is possible, or when environmental parameters exceed the safe range and equipment parameters are close to the alarm threshold. A Level 2 alarm applies when the parameter exceeds the normal threshold but is outside the emergency threshold, or when a serious problem equipment status code is received and the core parameters deviate from the normal threshold, or when the model predicts that the parameter will exceed the emergency threshold in 2-4 hours. An emergency alarm is activated when the parameter exceeds the emergency threshold, a fatal fault code is received and the equipment is abnormal, or when environmental parameters trigger a safety risk. Equipment status codes reflect the severity of equipment operation problems; this application provides warnings and alarms based on the severity of equipment operation problems.

[0043] Tiered response achieves differentiated handling through hardware and software collaboration: Early warnings only mark anomalies in yellow font and with a flashing icon on the software interface, pop up a non-mandatory pop-up window, and record the warning log, without triggering audible and visual alarms; Level 1 alarms trigger the audible and visual alarm module (intermittent buzzer sound, flashing yellow LED), push notifications containing suggested operations to the on-duty personnel's mobile app, repeating the push every 10 minutes if not confirmed, and encrypting and storing high-precision parameter curves; Level 2 alarms activate continuous audible and visual alarms (continuous buzzer sound, flashing red LED), automatically generate work orders containing maintenance instructions, synchronize them to the cloud and maintenance personnel, and send anomaly alerts to the instrument vehicle; Emergency alarms trigger high-decibel audible and visual alarms and alternating red and blue flashing, activate backup power, send linkage instructions containing risk type to the emergency command center and back up data, and simultaneously send an emergency shutdown instruction to the instrument vehicle, forming a complete closed loop from alert to handling.

[0044] High-precision parameter curves refer to continuous data curves generated by the wireless monitoring system when the equipment experiences a level one or higher alarm. These curves accurately reflect the subtle trends in parameter changes and provide refined data support for fault diagnosis and tracing.

[0045] Specifically, during normal equipment operation or early warning phases, parameter acquisition frequency is 1 second per acquisition, and the generated curve reflects the basic trend of change. When a Level 1 alarm is triggered, the edge computing module increases the acquisition frequency of the corresponding device's parameters and sends instructions to the multi-parameter wireless sensing terminal. The parameters of the corresponding device include lubricating oil pressure, hydraulic system pressure, and power end vibration frequency. The acquisition frequency is dynamically adjusted according to the urgency of the alarm, increasing to 0.1-0.5 seconds per acquisition for more urgent alarms. For example, increasing from 1 data point per second to 2-10 data points per second. These high-frequency acquired data are arranged sequentially by timestamp and plotted by software to form a continuous curve, clearly showing the instantaneous fluctuations, abrupt change points, and periodic fluctuation patterns of the parameters.

[0046] Furthermore, high-precision parameter curves are linked and annotated with information such as alarm trigger time, environmental parameter changes, and operation records. For example, a red dashed line marks the alarm trigger time in the high-precision parameter curve, and a gray shading marks the period of sudden increase in ambient temperature, helping maintenance personnel to intuitively locate the correlation before and after the anomaly occurred. These high-precision parameter curves are encrypted and stored locally and in the cloud, supporting operations such as zooming, cropping, and comparison. For example, the pressure curve of the current alarm can be overlaid with the curves of similar historical faults, and subtle differences in slope and amplitude can be used to determine whether the fault mode is consistent, providing data basis for accurate maintenance.

[0047] In short, high-precision parameter curves overcome the accuracy limitations of conventional parameter curves by increasing sampling density, preserving detailed features, and associating multi-dimensional information, making microscopic changes in equipment anomalies perceptible and knowable, and serving as a key bridge from data to decision-making.

[0048] In this embodiment, the emergency backup module includes a data caching mechanism. This mechanism automatically enters a low-power caching mode when the multi-parameter wireless sensing terminal fails to receive a response signal from the intelligent host receiving system for a preset number of consecutive cycles. It caches data and extends the data transmission interval. When the intelligent host receiving system recovers, the multi-parameter wireless sensing terminal retransmits the cached data to the intelligent host receiving system and restores the original data transmission interval. When the multi-parameter wireless sensing terminal enters the low-power caching mode, it reduces the operating current of the microcontroller unit and disables unnecessary functions of the wireless transmission unit. The data caching employs a cyclic overwrite mechanism, overwriting only the oldest stored data.

[0049] The emergency backup module includes a backup intelligent host. The backup intelligent host pre-stores the operating frequency band information and a pairing list of multi-parameter wireless sensor terminal address codes for each target monitoring system. When the intelligent host receiving system fails, the backup intelligent host automatically scans for multi-parameter wireless sensor terminal address codes within the current operating frequency band after powering on, completes pairing, and then receives data.

[0050] When multiple sets of the aforementioned wireless monitoring systems are deployed at the well site to form a target monitoring system, the various intelligent host receiving systems form a distributed monitoring network through networking. When one intelligent host receiving system fails, the surrounding intelligent host receiving systems automatically share its data storage and alarm functions.

[0051] It should be noted that, in this embodiment, the information interaction process under normal monitoring scenarios is as follows: During normal fracturing operations, each module achieves closed-loop information flow through multi-parameter acquisition, anti-interference transmission, and intelligent processing. The sensing units of the multi-parameter wireless sensing terminal collect data at preset frequencies, including the pressure and temperature of the lubricating oil at the fracturing truck and fracturing pump power end, the temperature of the fracturing truck's power system, the vibration frequency of the fracturing pump power end, the lubricating oil level at the fracturing pump power end, and data on the well site's ambient temperature, humidity, and dust concentration. These analog signals are transmitted in real-time to the signal processing unit. Upon receiving the signals, the signal processing unit first converts them into digital signals, then combines this with the sensor unit status and battery status detected by the fault self-checking unit to generate a standardized data frame containing a frame header, address code, fault code, equipment status code, and checksum. Simultaneously, it dynamically adjusts the acquisition frequency based on the fracturing well site's ambient temperature, humidity, and dust concentration data. For example, in high-dust environments, the temperature acquisition frequency is increased, and then the data frame is sent to the wireless transmission unit.

[0052] The wireless transmission unit sends data frames through an anti-interference wireless transmission link. This link uses frequency division multiplexing to allocate a unique operating frequency band for each target monitoring system and code division multiplexing to allocate a unique address code for each multi-parameter wireless sensor terminal, ensuring no data crosstalk. Furthermore, the high-frequency transparent ceramic material of the multi-parameter wireless sensor terminal's ceramic-metal composite shell and optimized antenna layout enhance signal penetration. The intelligent host receiving system's wireless transmission receiving module receives data frames through an external antenna and transmits them to an industrial all-in-one computer. The industrial all-in-one computer first verifies and removes invalid data, and then the edge computing module processes the data locally. This local processing includes parameter trend analysis. The software displays data in real time. If the parameters are normal, they are stored in a historical database with timestamps. If the parameters are abnormal, corresponding alarm levels are triggered based on the degree of exceeding thresholds. For example, a warning is only displayed via a pop-up window, while an emergency alarm is linked to the well site emergency command center. Simultaneously, data can be synchronized to the instrument vehicle's remote control system and the equipment management cloud platform via an industrial bus communication interface.

[0053] It should be noted that, in this embodiment, the information interaction process of the intelligent host receiving the system under abnormal scenarios is as follows: When the intelligent host receiving system malfunctions, the emergency backup module is activated to ensure uninterrupted information flow.

[0054] If the intelligent host receiving system unexpectedly shuts down, and the wireless transmission unit of the multi-parameter wireless sensing terminal fails to receive a response signal for a preset number of consecutive times, it immediately sends feedback to the signal processing unit, which triggers a low-power buffer mode. This mode extends the data transmission interval, reduces the operating current of the microcontroller unit, and disables unnecessary functions of the wireless transmission unit to reduce energy consumption. Simultaneously, it controls the wireless transmission unit to buffer the collected data according to timestamps, employing a cyclic overwrite mechanism to retain the latest data. Once the intelligent host receiving system is powered on again, its wireless transmission and receiving module immediately sends a data retransmission command to all paired multi-parameter wireless sensing terminals. Upon receiving the command, the signal processing unit controls the wireless transmission unit to retransmit the buffered data to the intelligent host receiving system in timestamp order. The intelligent host receiving system then inserts the data into the historical database according to the timestamp, completing the data chain.

[0055] If the intelligent host receiving system hardware fails, the staff will activate the backup intelligent host. Upon power-on, the backup intelligent host automatically scans the pre-stored operating frequency bands of each target monitoring system, detecting data frames from multi-parameter wireless sensor terminals within each band. When a data frame matching the pre-stored address code pairing list is identified, it automatically locks the corresponding operating frequency band, completes the pairing, and then takes over the data reception. After receiving the data frames, the backup intelligent host's wireless transmission and receiving module completes data parsing, display, storage, and alarm processing according to the normal monitoring scenario's information processing flow. Simultaneously, if a target monitoring system is deployed at the well site, surrounding intelligent host receiving systems will automatically share the data storage and alarm functions of the damaged host.

[0056] It should be noted that, in this embodiment, the information interaction process in a cross-system collaborative scenario is as follows: When the intelligent host receiving system interacts with external systems, it forms a collaborative information flow for monitoring, control, and response. When the software of the intelligent host receiving system detects abnormal parameters, such as the power system temperature exceeding the fire threshold, in addition to triggering an emergency alarm, the industrial computer sends a command to the instrument vehicle remote control system to suspend the fracturing pump via the industrial bus communication interface. After receiving the command, the instrument vehicle remote control system executes the shutdown operation and feeds back the operation result to the intelligent host receiving system. At the same time, the intelligent host receiving system sends a command to the well site fire protection system to activate the fire extinguishing equipment. After receiving the command, the well site fire protection system activates the sprinkler or dry powder fire extinguishing device and simultaneously feeds back the equipment activation status to the intelligent host receiving system. The software of the intelligent host receiving system displays the operating status of the external system in real time, forming a closed loop of information interaction to ensure rapid linkage and response when an anomaly occurs. In addition, the intelligent host receiving system can receive parameter adjustment instructions from the instrument vehicle remote control system through the industrial bus communication interface, such as modifying the lubricating oil pressure alarm threshold. The instructions are transmitted to the software part via the industrial computer all-in-one machine. After the software part adjusts the parameters, it sends them to the corresponding multi-parameter wireless sensing terminal through the wireless transmission receiving module. The wireless transmission unit of the multi-parameter wireless sensing terminal receives the instructions and transmits them to the signal processing unit. The signal processing unit updates the parameter configuration and completes the reverse information interaction.

[0057] Each module in the aforementioned wireless monitoring system can be implemented entirely or partially through software, hardware, or a combination thereof. These modules can be embedded in the processor of a computer device in hardware form or independent of it, or stored in the memory of the computer device in software form, so that the processor can call and execute the corresponding operations of each module.

[0058] In this embodiment, all embodiments and parameters appearing in the embodiments are illustrative and should not be construed as limiting the present invention in any way.

[0059] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A wireless monitoring system, characterized in that, include: Multi-parameter wireless sensing terminal, anti-interference wireless transmission link, intelligent host receiving system and emergency backup module; The multi-parameter wireless sensing terminal is used to collect data from fracturing operations and transmit the data through the anti-interference wireless transmission link. The anti-interference wireless transmission link is used to transmit data to the intelligent host receiving system; The intelligent host receiving system is used to receive, parse, and store the data, provide alerts for abnormal data conditions, allocate dedicated transmission time slots to each multi-parameter wireless sensing terminal, and set emergency time slots so that faulty multi-parameter wireless sensing terminals can transmit data first. Based on historical data, it predicts the trend of equipment operating parameters, identifies equipment fault types and generates maintenance suggestions, and establishes connections with the remote control system of the instrument vehicle for fracturing operations, the well site fire protection system, and the equipment management cloud platform to achieve data interaction and collaborative control. The emergency backup module is used to cache data or take over reception when the intelligent host receives a system malfunction.

2. The wireless monitoring system according to claim 1, characterized in that, The multi-parameter wireless sensing terminal includes a sensing unit, a signal processing unit, a wireless transmission unit, a power supply unit, and a fault self-testing unit. The sensing unit is connected to the signal processing unit and is used to collect data and send the signals obtained from the collected data to the signal processing unit. The signal processing unit is connected to the wireless transmission unit and the fault self-test unit, respectively, and is used to convert the signals sent by the sensing unit into digital signals, perform self-tests on the multi-parameter wireless sensing terminal, generate data frames with unique identifiers, and adjust the acquisition frequency of the device operating parameters according to the instructions received by the intelligent host system. The wireless transmission unit is used to send the data frames generated by the signal processing unit through an anti-interference wireless transmission link. The power supply unit is connected to the sensing unit, signal processing unit, wireless transmission unit, and fault self-test unit, respectively, and is used to supply power. The fault self-test unit is used to detect the status of the sensing unit and the power supply unit and generate device status codes and fault codes.

3. The wireless monitoring system according to claim 2, characterized in that, The sensing unit includes a pressure sensor, a temperature sensor, a vibration sensor, an oil level sensor, a temperature and humidity sensor, and a dust concentration sensor. The pressure sensor is used to collect the pressure of the lubricating oil at the power end of the fracturing truck and fracturing pump; the temperature sensor is used to collect the temperature of the lubricating oil at the power end of the fracturing pump and the temperature of the power system of the fracturing truck; the vibration sensor is used to collect the vibration frequency at the power end of the fracturing pump; the oil level sensor is used to collect the oil level of the lubricating oil at the power end of the fracturing pump; the temperature and humidity sensor is used to collect the ambient temperature and humidity of the fracturing well site; and the dust concentration sensor is used to collect the dust concentration at the fracturing well site. The data frame generated by the signal processing unit includes a frame header, address code, fault code, device status code, and check bit; wherein, the frame header is the system operating frequency band identifier, and the address code is the unique identifier of the multi-parameter wireless sensing terminal.

4. The wireless monitoring system according to claim 2, characterized in that, The power supply unit includes a battery and a battery management circuit; the battery management circuit is used to protect the battery from overcharge and over-discharge, and to calculate the battery's health status in real time; the fault codes generated by the fault self-test unit include sensor fault codes and low battery fault codes.

5. The wireless monitoring system according to claim 1, characterized in that, The anti-interference wireless transmission link adopts frequency division multiplexing and code division multiplexing; the frequency division multiplexing allocates a unique working frequency band to each target monitoring system; the code division multiplexing allocates a unique address code to each multi-parameter wireless sensing terminal; the intelligent host receiving system only receives data that matches the working frequency band and address code.

6. The wireless monitoring system according to claim 1, characterized in that, The intelligent host receiving system includes hardware and software components; The hardware component includes an industrial all-in-one computer, a wireless transmission and receiving module, an external antenna, an audible and visual alarm module, an edge computing module, and an industrial bus communication interface. The wireless transmission and receiving module is connected to the industrial all-in-one computer to receive and transmit data. The external antenna is connected to the wireless transmission and receiving module to enhance signal reception. The audible and visual alarm module is connected to the industrial all-in-one computer to issue alerts when data is abnormal. The edge computing module is connected to the industrial all-in-one computer for local data processing. The industrial bus communication interface is connected to the industrial all-in-one computer to enable data interaction between the intelligent host receiving system and external devices. The software component is used to display data in real time, identify and alert on faults, set alarm thresholds, manage historical data, export and print data, manage equipment, predict equipment operating parameter trends based on historical data, identify equipment fault types, and generate maintenance suggestions.

7. The wireless monitoring system according to claim 6, characterized in that, The alarm notification function of the software categorizes alarm levels into early warning, level one alarm, level two alarm, and emergency alarm. In the early warning state, a pop-up notification only appears on the software interface of the industrial computer all-in-one machine. In the level one alarm state, an audible and visual alarm is triggered, and an alarm message is pushed to the on-duty personnel's mobile application. In the level two alarm state, an audible and visual alarm is triggered, an alarm message is pushed to the on-duty personnel's mobile application, and a maintenance work order is automatically generated. In the emergency alarm state, an audible and visual alarm is triggered, an alarm message is pushed to the on-duty personnel's mobile application, a maintenance work order is automatically generated, and a linkage command is sent to the well site emergency command center. The historical data management function of the software includes storing data by timestamp, querying data by vehicle number and time range, and generating historical curves.

8. The wireless monitoring system according to claim 1, characterized in that, The emergency backup module includes a data caching mechanism. This mechanism automatically enters a low-power caching mode when the multi-parameter wireless sensor terminal fails to receive a response signal from the intelligent host receiving system for a preset number of consecutive cycles. This mode caches data and extends the data transmission interval. Once the intelligent host receiving system recovers, the multi-parameter wireless sensor terminal retransmits the cached data to the intelligent host receiving system and restores the original data transmission interval. When the multi-parameter wireless sensor terminal enters the low-power caching mode, it reduces the operating current of the microcontroller unit and disables unnecessary functions of the wireless transmission unit. The data caching employs a cyclic overwrite mechanism, overwriting only the oldest stored data.

9. The wireless monitoring system according to claim 8, characterized in that, The emergency backup module includes a backup intelligent host; the backup intelligent host pre-stores the working frequency band information and address code pairing list of each target monitoring system. When the intelligent host receiving system is damaged, the backup intelligent host automatically scans the address codes of multi-parameter wireless sensor terminals in the current working frequency band after powering on, and receives data after completing the pairing. When a target monitoring system is deployed at the well site, the various intelligent host receiving systems form a distributed monitoring network through networking. When one intelligent host receiving system fails, the surrounding intelligent host receiving systems automatically take over its data storage and alarm functions.

10. The wireless monitoring system according to claim 1, characterized in that, The data collected by the multi-parameter wireless sensing terminal includes: the pressure and temperature of the lubricating oil at the power end of the fracturing truck and fracturing pump, the temperature of the power system of the fracturing truck, the vibration frequency of the power end of the fracturing pump, the oil level of the lubricating oil at the power end of the fracturing pump, the pressure of the hydraulic system of the fracturing pump, the ambient temperature and humidity of the fracturing well site, and the dust concentration at the fracturing well site.

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