A variable frequency speed regulation and energy recovery cooperative drilling rig plunger pump energy-saving control method

Abstract

The application discloses a kind of energy-saving control method of frequency conversion speed regulation and energy recovery cooperation rig plunger pump, and relates to industrial control technical field.The method includes: monitoring the current working power of rig plunger pump at first working frequency, when power exceeds preset first working power interval, first working power time sequence is collected;According to the time sequence data, the geological adaptability coefficient is calculated using the pre-trained geological adaptability analyzer;Determine whether the working frequency needs to be adjusted, and determine the second working frequency and the corresponding second working power interval accordingly;Based on the second working frequency, frequency converter, energy storage device and energy recovery device are cooperatively controlled.The application realizes intelligent perception and self-adaptive adjustment to formation change, and significantly improves the energy efficiency and operation economy of rig plunger pump under complex geological conditions through the collaborative management of energy.

Description

Technical Field

[0001] This invention relates to the field of industrial control technology, specifically to an energy-saving control method for drilling rig plunger pumps that combines variable frequency speed regulation and energy recovery. Background Technology

[0002] In oil drilling operations, the plunger pump of the drilling rig is a core power unit, and its energy consumption accounts for a significant portion of the total energy consumption. Traditional control methods typically employ constant pressure or constant power control strategies, which are difficult to adapt to complex and variable geological conditions. When the lithology, hardness, or drillability of the formation changes, the load on the plunger pump fluctuates drastically, causing the motor's operating point to deviate from its high-efficiency range, resulting in a large waste of electrical energy. Simultaneously, during sudden load drops or braking, the regenerative energy generated by the motor is usually dissipated as heat through the braking resistor, which not only fails to be effectively utilized but may also exacerbate system heating, requiring additional cooling.

[0003] While existing technologies employ variable frequency speed control to adjust pump displacement in response to load changes, the speed control process often relies on operator experience or simple threshold judgments, lacking intelligent perception and forward-looking assessment of ground changes. This lagging and crude control method easily leads to frequent system starts and stops or severe power oscillations, affecting equipment lifespan and hindering refined energy-saving control. Furthermore, the acceleration demand during variable frequency speed control may impact the power grid, while the braking energy generated during deceleration is not recovered, leaving significant room for improvement in the overall energy utilization efficiency of the system. Summary of the Invention

[0004] This invention addresses the technical problems of high energy consumption and sluggish control response in existing drilling rig plunger pumps due to their difficulty in intelligently sensing and adapting to complex geological changes. It provides an energy-saving control method for drilling rig plunger pumps that combines variable frequency speed regulation and energy recovery.

[0005] The technical solution of the present invention to solve the above-mentioned technical problems is as follows: This invention provides an energy-saving control method for drilling rig plunger pumps that combines variable frequency speed regulation and energy recovery, comprising: Monitor the current operating power of the drilling rig plunger pump at a first operating frequency. When the current operating power exceeds the first operating power range, collect the first operating power time sequence, which includes the operating power at multiple time points after the current operating power exceeds the first operating power range. The geological adaptability coefficient is obtained based on the time series analysis of the first working power at the first working frequency, and the second working frequency and the second working power range are determined based on the geological adaptability coefficient. Based on the second operating frequency and the second operating power range, the drilling rig plunger pump is energy-saving controlled through the frequency converter, energy recovery device and energy storage device.

[0006] The beneficial effects of this invention are: Compared to existing technologies, this invention firstly employs an on-demand power timing acquisition mechanism to initiate data recording when power anomalies occur, effectively reducing the system's storage and computational burden. Secondly, utilizing a geological adaptability analyzer trained on historical data, it can accurately assess the matching degree between the operating frequency and geological conditions based on power timing characteristics, achieving intelligent identification of stratum changes. Thirdly, a progressive frequency adjustment scheme is adopted, switching between adjacent gears based on the adaptability coefficient and power trends, avoiding drastic fluctuations in operating conditions. Finally, during frequency adjustment, the inverter, energy storage device, and energy recovery device are coordinated and controlled, utilizing energy storage to assist in accelerating and improving response speed while also recovering and utilizing braking energy, comprehensively improving the energy efficiency and operational economy of the drilling rig plunger pump. Attached Figure Description

[0007] Figure 1 A flowchart illustrating an energy-saving control method for a drilling rig plunger pump that combines variable frequency speed regulation and energy recovery, provided by the present invention. Figure 2 This is a schematic diagram of the logic for energy-saving control of the piston pump of a drilling rig provided by the present invention. Detailed Implementation

[0008] 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.

[0009] In the description of this invention, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the stated features. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0010] In the description of this invention, the term "for example" is used to mean "used as an example, illustration, or description." Any embodiment described as "for example" in this invention is not necessarily to be construed as being more preferred or advantageous than other embodiments. The following description is provided to enable any person skilled in the art to make and use the invention. Details are set forth in the following description for purposes of explanation. It should be understood that those skilled in the art will recognize that the invention can be made without using these specific details. In other instances, well-known structures and processes will not be described in detail to avoid obscuring the description of the invention with unnecessary detail. Therefore, the invention is not intended to be limited to the embodiments shown, but is consistent with the broadest scope of the principles and features disclosed herein.

[0011] Examples, such as Figure 1 As shown, this embodiment of the invention provides an energy-saving control method for a drilling rig plunger pump that combines variable frequency speed regulation and energy recovery, including: S10: Monitor the current working power of the drilling rig plunger pump at the first working frequency. When the current working power exceeds the first working power range, collect the first working power time sequence. The first working power time sequence includes the working power at multiple time points after the current working power exceeds the first working power range. First, continuously monitor the current operating power of the drilling rig's plunger pump when it is running at the first operating frequency. This first operating frequency is the frequency at which the drilling rig's plunger pump is currently operating. Determine whether the current operating power exceeds the first operating power range, which is a preset allowable power range corresponding to the first operating frequency. This range is preset by statistically analyzing historical operating data and combining it with the equipment's operating characteristics.

[0012] When the current operating power exceeds the boundary of the first operating power range, the power data acquisition process is automatically triggered. This triggering mechanism ensures the targeted and timely nature of data acquisition, activating the recording function only when the power status is abnormal. Specifically, the acquisition process obtains the first operating power time series, which records the operating power values ​​at multiple consecutive time points after the current operating power exceeds the first operating power range. This fully reflects the dynamic changes after the power anomaly, thus providing a sufficient data foundation for subsequent analysis.

[0013] Through the above-described on-demand data acquisition steps, real-time monitoring of the drilling rig's plunger pump operating status and effective capture of key data were achieved, providing necessary data support for subsequent geological adaptability analysis and control decisions.

[0014] S20: Obtain the geological adaptability coefficient based on the time series analysis of the first working power at the first working frequency, and determine the second working frequency and the second working power range based on the geological adaptability coefficient; Specifically, the geological adaptability coefficient is obtained based on the time series analysis of the first operating power at the first operating frequency, including: Obtain the first operating power range corresponding to the first operating frequency; Based on the first operating power range, a geological adaptability analysis is performed on the first operating power time series to obtain the geological adaptability coefficient.

[0015] Specifically, the collected first operating power time series is analyzed to obtain the geological adaptability coefficient. This analysis process begins by obtaining the first operating power range corresponding to the current first operating frequency. This first operating power range is used as the evaluation benchmark to define the normal range of power operation at that specific frequency.

[0016] Secondly, based on the first operating power range, a geological adaptability analysis is performed on the collected first operating power time series. This analysis specifically compares the power time series data with a preset power range to assess the degree of matching between the drilling rig's plunger pump's operating status under current geological conditions and the preset operating conditions. The analysis results are output as a quantified geological adaptability coefficient, which objectively reflects the adaptability level of the current operating frequency to the actual geological conditions.

[0017] Specifically, based on the first operating power range, a geological adaptability analysis is performed on the time series of the first operating power to obtain a geological adaptability coefficient, including: The first geological adaptability analyzer is retrieved from the geological adaptability analyzer repository according to the first operating frequency, and the geological adaptability analyzer is constructed based on the first operating power range; The first operating power timing is input into the first geological adaptability analyzer to obtain the geological adaptability coefficient.

[0018] First, based on the current first operating frequency, the corresponding first geological adaptability analyzer is retrieved from a pre-established geological adaptability analyzer repository. This repository stores multiple dedicated geological adaptability analyzers matched with different operating frequencies, each of which is a dedicated analysis model built based on the operating power range at its corresponding operating frequency.

[0019] Specifically, the steps for building the geological adaptability analyzer repository include: Multiple operating frequencies of the drilling rig plunger pump are obtained, a target operating frequency is determined from the multiple operating frequencies, and the target operating power range of the target operating frequency is retrieved. Based on the target operating frequency, the working records of the plunger pumps of the same type of drilling rig are retrieved to obtain the working data of multiple plunger pumps of the same type. The working data of each plunger pump of the same type includes the historical working power time series collected when the working power exceeds the target working power range at the target operating frequency. Based on the historical working power time series, a sample working power time series set is constructed, and based on the target working power interval, the geological adaptability coefficients of each sample working power time series in the sample working power time series set are labeled to construct a sample geological adaptability coefficient set. Using the sample working power time series set as input and the sample geological adaptability coefficient set as target output, a geological adaptability analyzer for the target working frequency is trained and generated. Following the method for generating the geological adaptability analyzer for the target operating frequency, geological adaptability analyzers for other operating frequencies are generated, resulting in multiple geological adaptability analyzers. The multiple operating frequencies are associated with and stored with the multiple geological adaptability analyzers to form the geological adaptability analyzer repository.

[0020] The process of building the geological adaptability analyzer repository is accomplished through the following steps: First, obtain multiple operating frequencies that the drilling rig's plunger pump may use during operation. Select one of these frequencies as the target operating frequency for the current construction process, and retrieve the target operating power range corresponding to this target operating frequency. This target operating power range defines the normal power range for operation at this specific frequency. This range is determined by analyzing historical stable operating data of the drilling rig's plunger pump at the target operating frequency, combined with the equipment's rated parameters and engineering practice experience.

[0021] Secondly, using the target operating frequency as the search criterion, the operating records of similar drilling rig plunger pumps are queried in the historical database. This search operation yields multiple sets of operating data for the same type of plunger pump. The historical database is a dedicated dataset built upon long-term accumulation of actual operating data of drilling rig plunger pumps under different geological conditions and operating parameters. Specifically, the obtained operating data for the same type of plunger pump includes historical operating power time series collected when the drilling rig plunger pump operates at the target operating frequency and its operating power exceeds the target operating power range.

[0022] Furthermore, a sample working power time series is constructed based on the collected historical working power time series. Based on the determined target working power interval, a geological adaptability coefficient is labeled for each sample working power time series in the sample working power time series, thereby constructing a corresponding sample geological adaptability coefficient set.

[0023] Specifically, based on the target working power range, the geological adaptability coefficients of each sample working power time series in the sample working power time series set are labeled to construct a sample geological adaptability coefficient set, including: Traverse the sample operating power time series set to obtain the first sample operating power time series; The total number of time points in the first sample working power time series is counted, and the number of time points in the first sample working power time series where the working power is within the target working power range is counted to obtain the number of qualified time points; Calculate the ratio of the number of qualified time points to the total number of time points, and use the ratio of time points as the geological adaptability coefficient of the first sample corresponding to the working power time series of the first sample. The geological adaptability coefficient of the first sample is added to the set of geological adaptability coefficients of the sample.

[0024] First, the sample operating power time series is traversed, and the first sample operating power time series to be processed is selected, namely the first sample operating power time series. This first sample operating power time series contains a series of power sample values ​​arranged in chronological order.

[0025] Secondly, statistical analysis is performed on the operating power time series of the first sample. The total number of time points included in the operating power time series of the first sample is calculated, and the number of specific time points in which the operating power value falls within the target operating power range is counted. The latter is recorded as the number of qualified time points.

[0026] Then, the ratio between the number of qualified time points and the total number of time points is calculated, i.e., the time point ratio. This time point ratio reflects the proportion of time during which the power value is within the normal range within the statistical time period. This time point ratio is used as the geological adaptability coefficient corresponding to the working power time series of the first sample, and is called the first sample geological adaptability coefficient.

[0027] Finally, the calculated geological adaptability coefficient of the first sample is added to the sample geological adaptability coefficient set. By repeating the above steps and traversing each sample working power time series in the sample working power time series set, the coefficient labeling work for the entire sample working power time series set can be completed, ultimately forming a complete sample geological adaptability coefficient set.

[0028] The final sample geological adaptability coefficient set completely includes the quantitative evaluation index corresponding to the working power time series of all samples. This sample geological adaptability coefficient set strictly corresponds to the sample working power time series set and can be used as the target output in the supervised learning training process to guide the model training of the geological adaptability analyzer, thereby establishing an accurate mapping relationship from power time series characteristics to the degree of geological adaptability.

[0029] Furthermore, a geological adaptability analyzer is constructed and trained using a sample power time series set as training input and a sample geological adaptability coefficient set as target output. This analyzer learns the nonlinear mapping relationship between power time series features and geological adaptability coefficients through machine learning algorithms, and its training process is completed using supervised learning. For example, deep neural networks, support vector machines, or random forests can be selected as the basic architecture. Iterative optimization algorithms continuously adjust the model's internal parameters to minimize the error between the predicted coefficients output by the model and the true values ​​labeled in the sample geological adaptability coefficient set, ultimately obtaining a geological adaptability analyzer with good generalization ability.

[0030] For example, since there is a highly nonlinear and complex correlation between power time series characteristics and geological adaptability coefficient, and neural network models have significant advantages in time series pattern recognition and dynamic feature extraction, a neural network model is chosen to construct this geological adaptability analyzer.

[0031] Specifically, this geological adaptability analyzer mainly consists of an input layer, a feature extraction layer, and a coefficient output layer. The input layer receives standardized power time-series data, which contains power sample value sequences from multiple consecutive time points. The feature extraction layer employs a one-dimensional convolutional neural network combined with a long short-term memory (LSTM) network structure. The convolutional layers are responsible for extracting local fluctuation features from the power sequence, while the LSM network captures long-term dependencies in power changes. The number of neurons in the hidden layers is configured according to the power sequence length and feature dimension. Each neural network layer uses the ReLU activation function to enhance nonlinear expressive power, and Dropout layers are embedded between network layers with a dropout rate set between 0.3 and 0.5 to effectively suppress model overfitting and improve its generalization performance. The output layer uses the Sigmoid activation function to map the finally extracted features to continuous values ​​between 0 and 1, serving as geological adaptability coefficients.

[0032] During training, key hyperparameters included a learning rate of 0.0005, 200 training epochs, and a batch size of 32. The learning rate was set to balance training stability and convergence accuracy; the number of training epochs ensured the model fully learned the geological response patterns in the power sequences; and the batch size balanced training efficiency with gradient stability. Specifically, supervised learning was employed, using the sample power time series as the input sample set and the sample geological fitness coefficient set as the target output, i.e., the label sample set. The input sample set and the corresponding label sample set were divided into training, validation, and test sets in a 7:2:1 ratio.

[0033] Furthermore, the power time series data from the training set is used as input, and the corresponding geological fitness coefficients of the samples are used as supervision signals. The network weight parameters are iteratively optimized using a backpropagation algorithm combined with the Adam optimizer. The mean squared error loss function is used to measure the deviation between the predicted geological fitness coefficients and the sample geological fitness coefficients. The training process is monitored using a validation set. When the validation set loss function value no longer decreases for several consecutive rounds and the model prediction error is below a predetermined threshold, such as 0.05, training is terminated, resulting in a converged geological fitness analyzer. This geological fitness analyzer can effectively capture the complex nonlinear relationship between power time series characteristics and geological conditions, achieving accurate geological fitness assessment.

[0034] Then, the above construction process is repeated, taking each of the remaining operating frequencies of the drilling rig's plunger pump as the new target operating frequencies, and generating corresponding geological adaptability analyzers in the same way. This ultimately yields multiple geological adaptability analyzers covering all operating frequencies.

[0035] Finally, a mapping relationship is established between operating frequencies and multiple geological adaptability analyzers. Multiple operating frequencies are associated with and stored with their corresponding geological adaptability analyzers, forming a complete geological adaptability analyzer repository. This repository provides fundamental support for quickly calling appropriate geological adaptability analyzers during real-time control.

[0036] Furthermore, the first operating power time series data acquired in step S10 is completely input into the first geological adaptability analyzer. This geological adaptability analyzer processes the input power time series data using an internal algorithm, analyzes the dynamic characteristics and patterns of power changes, and outputs a geological adaptability coefficient. This geological adaptability coefficient objectively reflects the degree of matching between the power characteristics at the current operating frequency and the power characteristics under ideal operating conditions, thereby accurately assessing the adaptability of the current geological conditions and operating parameters.

[0037] Furthermore, after obtaining the geological adaptability coefficient, the subsequent control strategy is determined based on the value of the geological adaptability coefficient.

[0038] Specifically, when the geological adaptability coefficient is greater than or equal to the adaptability coefficient threshold, the first operating frequency is kept unchanged, the first operating frequency is used as the second operating frequency, and the first operating power range is used as the second operating power range.

[0039] When the geological adaptability coefficient is greater than or equal to the preset adaptability coefficient threshold, it indicates that the drilling rig plunger pump's operating state at the current first operating frequency has a good match with the geological conditions. Maintaining the existing operating parameters is the optimal choice at this point; therefore, the first operating frequency is directly determined as the second operating frequency, and the first operating power range is extended as the second operating power range to avoid energy loss and equipment disturbance caused by unnecessary frequency adjustments. The preset adaptability coefficient threshold is a critical value determined by analyzing the distribution of geological adaptability coefficients corresponding to the system's stable operating state in historical drilling data. This threshold is set comprehensively based on equipment characteristics, geological conditions, and engineering accuracy requirements. For example, this threshold can be set to 0.85, indicating that when the evaluation coefficient reaches 85% or higher, the current operating frequency is considered to meet the stable operation requirements of the geological conditions.

[0040] When the geological adaptability coefficient is less than the preset adaptability coefficient threshold, it indicates that the current operating frequency is not well matched with the geological conditions. Maintaining the original frequency will cause the system to continue operating in an inefficient or overloaded state, which will not only increase energy consumption but may also accelerate equipment wear. Therefore, it is necessary to adjust to a more suitable second operating frequency so that the output characteristics of the plunger pump can better adapt to the formation load requirements, thereby returning to the efficient operating range.

[0041] Specifically, the second operating frequency and the second operating power range are determined based on the geological adaptability coefficient, including: The geological adaptability coefficient is compared with a preset adaptability coefficient threshold. When the geological adaptability coefficient is less than the adaptability coefficient threshold, the trend of power change in the first working power time series is analyzed to determine the direction of power change; Multiple operating frequencies of the drilling rig plunger pump are obtained, and a second operating frequency is determined from the multiple operating frequencies based on the power change direction and the first operating frequency; The corresponding second operating power range is retrieved based on the second operating frequency.

[0042] Specifically, when the geological adaptability coefficient is less than the adaptability coefficient threshold, it indicates that the current working frequency does not meet the requirements for matching with the geological conditions. In this case, trend analysis of the first working power time series is needed to determine the direction of power change. This analysis process is achieved through the following steps: First, the acquired first operating power time series is preprocessed using a moving average filtering algorithm to eliminate instantaneous fluctuations, resulting in a smoothed power change curve. The window width of this filtering algorithm is set according to the sampling frequency and operating conditions, typically selecting 5 to 10 sampling points as the window size. Second, linear regression analysis is applied to the smoothed power sequence. Using time points as independent variables and power values ​​as dependent variables, a trend line of power change over time is obtained by fitting using the least squares method. The slope of this trend line quantitatively characterizes the magnitude and direction of power change: a positive slope indicates a continuously increasing power characteristic; a negative slope indicates a continuously decreasing power characteristic.

[0043] In addition, to enhance the reliability of the judgment, the difference between the beginning and end of the power sequence can be calculated as an auxiliary criterion. The average value of several sampling points at the end of the power time series is compared with the average value of several sampling points at the beginning. When the mean at the end is significantly greater than the mean at the beginning, it is judged as an increasing trend; otherwise, it is judged as a decreasing trend.

[0044] Finally, by combining the positive and negative directions of the linear regression slope and the comparison results of the first and last differences, it was determined whether the power change direction was continuously increasing or continuously decreasing.

[0045] Furthermore, multiple preset selectable operating frequencies of the drilling rig's plunger pump are obtained. Based on the determined power change direction and the current first operating frequency, a second operating frequency is determined from among the multiple selectable operating frequencies.

[0046] Specifically, determining a second operating frequency from among multiple operating frequencies based on the power change direction and the first operating frequency includes: When the power change direction is power increase, select the working frequency that is adjacent to the first working frequency and is lower than the first working frequency from multiple working frequencies as the second working frequency. When the power change direction is decreasing, the operating frequency that is adjacent to the first operating frequency and is greater than the first operating frequency is selected as the second operating frequency from among multiple operating frequencies.

[0047] Specifically, the frequency selection strategy is based on the following mechanism: the direction of power change directly reflects the matching relationship between the drilling rig plunger pump load and the current operating frequency. When the power change direction shows a continuous increasing trend, it indicates that the current first operating frequency setting is relatively high, causing the plunger pump output power to exceed the actual geological load requirements, and the system is operating in an overload risk state. At this time, the operating frequency should be appropriately reduced. Therefore, among several selectable operating frequencies, the next lower value adjacent to the first operating frequency and with a smaller value is selected as the second operating frequency.

[0048] Meanwhile, when the power change shows a continuously decreasing trend, it indicates that the current first operating frequency setting is relatively low, the plunger pump output power cannot overcome the formation resistance, and the system is in an underload operating state. At this time, it is necessary to appropriately increase the operating frequency. Therefore, among several selectable operating frequencies, the next higher value adjacent to the first operating frequency and with a larger value is selected as the second operating frequency.

[0049] Finally, based on the determined second operating frequency, the corresponding second operating power range is retrieved. This power range defines the normal range of power operation at the second operating frequency, providing a monitoring benchmark for subsequent energy-saving control.

[0050] In summary, through the above steps, the working frequency and power range were adjusted in a coordinated manner based on geological adaptability assessment, ensuring that the drilling rig plunger pump always operates under the optimal conditions adapted to geological conditions.

[0051] S30: Based on the second operating frequency and the second operating power range, energy-saving control is performed on the drilling rig plunger pump through the frequency converter, energy recovery device and energy storage device.

[0052] Specifically, based on the second operating frequency and the second operating power range, energy-saving control of the drilling rig plunger pump is achieved through the frequency converter, energy recovery device, and energy storage device, including: When the second operating frequency is greater than the first operating frequency, the operating frequency of the drilling rig plunger pump is adjusted from the first operating frequency to the second operating frequency through the frequency converter, and at the same time, the energy storage device is controlled to release electrical energy to provide the auxiliary power required for the frequency converter to accelerate. When the second operating frequency is lower than the first operating frequency, the operating frequency of the drilling rig plunger pump is adjusted from the first operating frequency to the second operating frequency through the frequency converter. At the same time, the energy recovery device is activated to recover the electrical energy generated during the motor braking process and store it in the energy storage device.

[0053] When the second operating frequency is equal to the first operating frequency, the inverter output frequency remains unchanged, and the energy storage device and energy recovery device are in standby mode.

[0054] like Figure 2 As shown, based on the determined second operating frequency and the corresponding second operating power range, the frequency converter, energy recovery device, and energy storage device are coordinated and controlled to implement energy-saving operation control for the drilling rig plunger pump. Specifically, this control process is divided into three cooperative control modes according to the relative relationship between the second operating frequency and the current first operating frequency.

[0055] When the second operating frequency is determined to be higher than the current first operating frequency, the control process first uses a frequency converter to increase the operating frequency of the drill rig plunger pump's drive motor from the first operating frequency to the second operating frequency. During the frequency increase and acceleration process, the energy storage device is simultaneously controlled to discharge, providing auxiliary power for motor acceleration. This coordinated control measure effectively shares the instantaneous power burden on the power grid during motor acceleration, both suppressing the impact on the power grid and improving the overall energy efficiency of the system by utilizing stored energy.

[0056] When the second operating frequency is determined to be lower than the current first operating frequency, the control process also reduces the operating frequency of the drive motor from the first operating frequency to the second operating frequency via the frequency converter. During this frequency reduction and deceleration process, the energy recovery device is simultaneously activated. This energy recovery device effectively captures, converts, and transmits the regenerative electrical energy generated during motor braking to the energy storage device for storage. This coordinated control measure avoids the conventional dissipation and waste of braking energy, converting it into reusable reserve energy and realizing the recycling of energy.

[0057] Furthermore, when the second operating frequency equals the first operating frequency, it indicates that after geological adaptability assessment, the current operating parameters have been determined to be well-matched with the geological conditions, and no frequency adjustment is required. Under this condition, the control system maintains the inverter's existing output frequency, and the drilling rig's plunger pump continues to operate stably at the current operating frequency. Simultaneously, the energy storage device maintains its current charge state and does not perform charging or discharging operations; the energy recovery device also suspends its operating cycle. Both enter a low-power standby state, maintaining only necessary monitoring functions.

[0058] Through coordinated control in the above three scenarios, not only was the system power relatively stable during frequency adjustment, but also the intelligent flow and efficient management of energy between the energy storage device and the load were achieved, ultimately achieving the energy-saving operation goal of the drilling rig plunger pump.

[0059] In summary, the embodiments of this application have at least the following technical effects: Compared to existing technologies, this invention firstly employs an on-demand power timing acquisition strategy, initiating data recording only when power anomalies occur, effectively saving system storage resources and computational overhead. Secondly, it introduces a geological adaptability analyzer trained on historical data, capable of accurately quantifying and evaluating the matching degree between the operating frequency and geological conditions based on the dynamic pattern of power timing, achieving intelligent perception and forward-looking judgment of stratum changes. Thirdly, combining the geological adaptability coefficient and power change trend, a gradual frequency adjustment strategy is adopted, selecting adjacent gears for switching among multiple discrete gears, avoiding drastic jumps and power oscillations at the operating point, ensuring control stability and equipment safety. Finally, throughout the frequency adjustment process, the intelligent coordination of the inverter, energy storage device, and energy recovery device's operating status is monitored. The energy storage device assists in acceleration to improve response speed, while the energy recovery device effectively recovers and stores braking energy, achieving optimized energy management and recycling, thereby significantly improving the overall energy efficiency and operational economy of the drilling rig plunger pump under complex geological conditions.

[0060] It should be noted that the order of the embodiments described above is merely for descriptive purposes and does not represent the superiority or inferiority of the embodiments. Furthermore, the above description focuses on specific embodiments of this specification. Additionally, the processes depicted in the accompanying drawings do not necessarily require a specific or sequential order to achieve the desired results. In some implementations, multitasking and parallel processing are possible or may be advantageous.

[0061] The above description is only a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

[0062] This specification and accompanying drawings are merely illustrative examples of this application and are intended to cover any and all modifications, variations, combinations, or equivalents within the scope of this application. Clearly, those skilled in the art can make various alterations and modifications to this application without departing from its scope. Therefore, if such modifications and modifications fall within the scope of this application and its equivalents, this application intends to include such modifications and modifications.

Claims

1. A variable frequency speed regulation and energy recovery coordinated energy-saving control method for a rig plunger pump, characterized in that, The method includes: Monitor the current operating power of the drilling rig plunger pump at a first operating frequency. When the current operating power exceeds the first operating power range, collect the first operating power time sequence, which includes the operating power at multiple time points after the current operating power exceeds the first operating power range. The geological adaptability coefficient is obtained based on the time series analysis of the first working power at the first working frequency, and the second working frequency and the second working power range are determined based on the geological adaptability coefficient. The determination of the second operating frequency and the second operating power range based on the geological adaptability coefficient includes: The geological adaptability coefficient is compared with a preset adaptability coefficient threshold. When the geological adaptability coefficient is less than the adaptability coefficient threshold, the trend of power change in the first working power time series is analyzed to determine the direction of power change; Multiple operating frequencies of the drilling rig plunger pump are obtained, and a second operating frequency is determined from the multiple operating frequencies based on the power change direction and the first operating frequency; The corresponding second operating power range is retrieved based on the second operating frequency; The process of determining a second operating frequency from among multiple operating frequencies based on the power change direction and the first operating frequency includes: When the power change direction is power increase, select the working frequency that is adjacent to the first working frequency and is lower than the first working frequency from multiple working frequencies as the second working frequency. When the power change direction is decreasing, select the operating frequency that is adjacent to the first operating frequency and is greater than the first operating frequency from multiple operating frequencies as the second operating frequency. Based on the second operating frequency and the second operating power range, the drilling rig plunger pump is energy-saving controlled through a frequency converter, an energy recovery device, and an energy storage device. Specifically, based on the second operating frequency and the second operating power range, energy-saving control of the drilling rig plunger pump is achieved through a frequency converter, an energy recovery device, and an energy storage device, including: When the second operating frequency is greater than the first operating frequency, the operating frequency of the drilling rig plunger pump is adjusted from the first operating frequency to the second operating frequency through the frequency converter, and at the same time, the energy storage device is controlled to release electrical energy to provide the auxiliary power required for the frequency converter to accelerate. When the second operating frequency is lower than the first operating frequency, the operating frequency of the drilling rig plunger pump is adjusted from the first operating frequency to the second operating frequency through the frequency converter. At the same time, the energy recovery device is activated to recover the electrical energy generated during the motor braking process and store it in the energy storage device.

2. The energy-saving control method for the frequency conversion speed regulation and energy recovery coordinated drilling rig plunger pump according to claim 1, characterized in that, The geological adaptability coefficient is obtained based on the time series analysis of the first working power at the first working frequency, including: Obtain the first operating power range corresponding to the first operating frequency; Based on the first operating power range, a geological adaptability analysis is performed on the first operating power time series to obtain the geological adaptability coefficient.

3. The energy-saving control method for the frequency conversion speed regulation and energy recovery coordinated drilling rig plunger pump according to claim 2, characterized in that, Based on the first operating power range, a geological adaptability analysis is performed on the first operating power time series to obtain a geological adaptability coefficient, including: The first geological adaptability analyzer is retrieved from the geological adaptability analyzer repository according to the first operating frequency. The first geological adaptability analyzer is constructed based on the first operating power range. The first operating power timing is input into the first geological adaptability analyzer to obtain the geological adaptability coefficient.

4. The energy-saving control method for a drilling rig plunger pump with coordinated variable frequency speed regulation and energy recovery as described in claim 3, characterized in that, The steps for building the geological adaptability analyzer repository include: Multiple operating frequencies of the drilling rig plunger pump are obtained, a target operating frequency is determined from the multiple operating frequencies, and the target operating power range of the target operating frequency is retrieved. Based on the target operating frequency, the working records of the plunger pumps of the same type of drilling rig are retrieved to obtain the working data of multiple plunger pumps of the same type. The working data of each plunger pump of the same type includes the historical working power time series collected when the working power exceeds the target working power range at the target operating frequency. Based on the historical working power time series, a sample working power time series set is constructed, and based on the target working power interval, the geological adaptability coefficients of each sample working power time series in the sample working power time series set are labeled to construct a sample geological adaptability coefficient set. Using the sample working power time series set as input and the sample geological adaptability coefficient set as target output, a geological adaptability analyzer for the target working frequency is trained and generated. Following the method for generating the geological adaptability analyzer for the target operating frequency, geological adaptability analyzers for other operating frequencies are generated, resulting in multiple geological adaptability analyzers. The multiple operating frequencies are associated with and stored with the multiple geological adaptability analyzers to form the geological adaptability analyzer repository.

5. The energy-saving control method for a drilling rig plunger pump with variable frequency speed regulation and energy recovery synergy as described in claim 4, characterized in that, Based on the target working power range, geological adaptability coefficients are labeled for each sample working power time series in the sample working power time series set, and a sample geological adaptability coefficient set is constructed, including: Traverse the sample operating power time series set to obtain the first sample operating power time series; The total number of time points in the first sample working power time series is counted, and the number of time points in the first sample working power time series where the working power is within the target working power range is counted to obtain the number of qualified time points; Calculate the ratio of the number of qualified time points to the total number of time points, and use the ratio of time points as the geological adaptability coefficient of the first sample corresponding to the working power time series of the first sample. The geological adaptability coefficient of the first sample is added to the set of geological adaptability coefficients of the sample.

6. The energy-saving control method for a drilling rig plunger pump with variable frequency speed regulation and energy recovery synergy as described in claim 1, characterized in that, When the geological adaptability coefficient is greater than or equal to the adaptability coefficient threshold, the first working frequency is kept unchanged, the first working frequency is used as the second working frequency, and the first working power range is used as the second working power range.

7. The energy-saving control method for a drilling rig plunger pump with variable frequency speed regulation and energy recovery synergy as described in claim 1, characterized in that, When the second operating frequency is equal to the first operating frequency, the inverter output frequency remains unchanged, and the energy storage device and energy recovery device are in standby mode.

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