A top drive communication system and method

Abstract

The present application relates to the field of oil drilling industry, and particularly relates to a top drive communication system and method, the system comprising a first signal coupling device, a second signal coupling device and a signal conversion device, and the first data receiving and sending end and the second data receiving and sending end of the signal conversion device are mechanically separated from each other, the signal conversion device is connected to a communication cable between the top drive and a distributed substation of the top drive, one end of the first signal coupling device is connected to a main controller of the top drive, the other end of the first signal coupling device is connected to a power transmission cable between a power supply in an electric control room and a direct current power supply for directly supplying power to the distributed substation, and the two ends of the second signal coupling device are respectively connected to the power transmission cable and the distributed substation, on the one hand, the function of uninterrupted signal transmission during the rotation process of the rotary head is realized, and the situation that the line is pulled off due to too large rotation angle of the rotary head is avoided, on the other hand, the cable and the signal line do not need to be rearranged, and the cost is low.

Description

Technical Field

[0001] This invention relates to the field of oil drilling and production, and in particular to a top drive communication system and method. Background Technology

[0002] Top drive, short for top-driven drilling rig, is a drilling device installed inside the derrick and suspended by a traveling block. It allows direct rotation of the drill pipe from the upper space of the derrick, feeding it downwards along a dedicated guide rail to complete various drilling and completion operations such as drill pipe rotation, drilling fluid circulation, stand connection, connection and disconnection, reaming, and casing installation. This device significantly improves drilling capability and efficiency and has become a standard product in the oil drilling industry.

[0003] To enable the complex operation of the top drive, the top drive is equipped with a complete control system, which consists of: the driller's table, the electrical control room, communication cables, and the body station (the communication station located on the top drive body).

[0004] The electrical control room houses the system's main controller. This controller controls the drive system and auxiliary systems (the drive system being the power system of the top drive motor, including: incoming line cabinet, frequency converter, power cable, and main motor; the auxiliary system being the top drive's status monitoring and hydraulic system control system) via communication. It also communicates with the driller's platform and the body station. Upon receiving commands from the driller's platform, the main controller transmits control signals to the actuators on the top drive body via control cables to control the top drive, or receives sensor signals from the top drive body to achieve top drive status awareness. Traditionally, the main controller of a top drive communicates with the body station in two ways, specifically:

[0005] 1) The main controller connects to sensors or electronic actuators via multi-core cables, enabling direct communication between them. The multi-core cables are bundled together to form a communication cable bundle, with one end connected to the terminals of the various sensors and electronic actuators inside the top drive housing, and the other end connected to the main controller in the electrical control room. To allow the top drive to move vertically within the derrick space, a towed mobile cable is used. Therefore, the mobile cable of the top drive must withstand harsh natural environments such as high temperatures in summer and freezing temperatures in winter, as well as repeated bending and dragging.

[0006] 2) The main controller connects to the distributed substations via fieldbus. When using fieldbus communication, various sensors and electronic actuators mounted on the top drive unit are connected to the input / output terminals of the distributed substations located inside the unit's enclosure, communicating with the system's main controller via the substations. Using fieldbus communication, the communication medium between the control room and the main unit can be simplified from dozens of core cables to a single or multiple pairs of twisted-pair communication cables.

[0007] As top drives are used more widely, operating conditions become more complex, and operating environments become more severe, a growing number of drilling auxiliary tools and drilling processes have been developed around top drives. Examples include hydraulic lifting clamps, precise control technology for lifting ring inclination angles, and precise control technology for slewing head speed. The foundation for these auxiliary tools, processes, and technologies lies in the top drive communication system possessing comprehensive communication functions and good scalability. However, current top drive communication technologies are still insufficient to meet the requirements of these new auxiliary tools and processes. The main problems are as follows:

[0008] 1) The intelligent upgrade of the top drive is an indispensable step in its development. This upgrade relies on the increasing number of sensors and electronic actuators. When the top drive's main station and the main controller communicate directly via cable, the number of cores in the communication cable needs to increase continuously with the addition of sensors and electronic actuators (at least two additional cores are required for each additional sensor or electrical actuator). This necessitates the use of communication cable bundles with even more cores, sometimes increasing the number by several or even dozens of cores. The existing mechanical structure of drilling rigs and top drives can no longer accommodate the ever-increasing thickness and weight of these communication cable bundles. Therefore, traditional multi-core cable communication methods limit the functional expansion of the top drive.

[0009] 2) When using bus communication, control signals from dozens of sensors and electronic actuators can be transmitted over a single network cable, avoiding the need to continuously increase the number of cables as the number of sensors and electronic actuators increases. However, the transmission distance of the fieldbus is limited. The theoretical maximum transmission distance of an Ethernet-based fieldbus is 100 meters; otherwise, repeater devices are required. The installation distance between the top drive unit and the electrical control room is usually over 110 meters. The drilling site environment generally cannot meet the conditions for installing repeater devices. Therefore, fiber optics are commonly used instead of network cables in engineering. From a communication perspective, fiber optic communication has advantages such as large capacity, long transmission distance, and strong anti-interference capability. Practical application results also show that fiber optics can effectively replace network cables in top drive fieldbus communication. Currently, top drive manufacturers primarily use fiber optics as the communication carrier for their fieldbuses.

[0010] 3) The brittleness and poor mechanical strength of optical fibers become increasingly prominent as the operating environment of top drives becomes more severe. For example, in cold environments, optical fibers become hard and brittle, and improper insertion or removal during top drive body vibration or maintenance can easily cause fiber optic connectors to break. Fiber optic splicing requires specialized tools, equipment, and techniques, and users generally cannot repair it themselves on-site. The entire communication cable must be replaced, requiring a significant investment of manpower and resources.

[0011] Another problem faced by the top drive communication system is that a series of status signals, such as the status signals of the hydraulic lifting chuck, the locking signal of the back clamp, and the tilt angle of the lifting ring, need to be transmitted back to the main controller to achieve functions such as linkage with the drilling rig and status monitoring. These sensors differ from the various sensors currently installed on the top drive in that:

[0012] 1) The sensors and electronic actuators of the existing top drive are all mounted on fixed parts of the top drive body. When the top drive is working, the sensors or electronic actuators remain relatively stationary with respect to the body box. Therefore, the sensor wiring does not change with the working state of the top drive and can be directly connected to the body box.

[0013] 2) When the hydraulic clamp opening and closing sensor, back clamp locking sensor and lifting ring tilt angle sensor are working, they generally need to rotate with the slewing head. That is, the distance between the sensor and the electronic actuator and the main body box changes with the working state of the top drive. If the wiring of these sensors is directly connected to the main body box, the wiring will be broken when the slewing head rotates too much.

[0014] Currently, there are few relevant patents, papers, and research in China that provide detailed descriptions of the communication system of top drives and offer improvement measures. Summary of the Invention

[0015] The technical problem to be solved by the present invention is to address the shortcomings of the prior art by providing a top-drive communication system and method.

[0016] The technical solution of the top-drive communication system of the present invention is as follows:

[0017] The device includes a first signal coupling device, a second signal coupling device, and a signal conversion device with a first data receiving and transmitting end and a second data receiving and transmitting end, wherein the first data receiving and transmitting end and the second data receiving and transmitting end are mechanically separated from each other. The signal conversion device is used to connect to the communication cable between the top drive and the distributed substation of the top drive. One end of the first signal coupling device is connected to the main controller of the top drive, and the other end of the first signal coupling device is connected to the power transmission cable between the power supply in the power control room and the DC power supply used to directly supply power to the distributed substation. The two ends of the second signal coupling device are respectively connected to the power transmission cable and the distributed substation.

[0018] The first signal coupling device receives the control signal corresponding to the control command issued by the main controller, couples the control signal into the power transmission cable, and sends it to the second signal coupling device;

[0019] The second signal coupling device receives the control signal and sends the control signal sequentially through the distributed substation and the signal conversion device to the top drive, so that the top drive obtains the control command according to the control signal and executes it.

[0020] The beneficial effects of the top-drive communication system of the present invention are as follows:

[0021] On the one hand, by setting up a signal conversion device with a first data receiving and transmitting end and a second data receiving and transmitting end that are mechanically separated from each other, the signal transmission is uninterrupted during the rotation of the top drive rotary head, avoiding the situation where the line is torn due to the excessive rotation angle of the top drive rotary head. On the other hand, data communication is carried out through the existing power transmission cable, which does not require the re-layout of cables and signal lines, can transmit over long distances, is not easily damaged, and has low cost.

[0022] Based on the above solution, the top drive communication system of the present invention can be further improved as follows.

[0023] Furthermore, the second signal coupling device receives the field measurement signal sent by the distributed substation, couples the field measurement signal into the power transmission cable between the power supply in the power control room and the DC power supply used to directly supply power to the top drive, and sends it to the first signal coupling device. The top drive generates the field measurement signal corresponding to the field measurement data and sends it to the distributed substation through the signal conversion device.

[0024] The first signal coupling device receives and sends the field measurement signal to the main controller, so that the main controller can obtain the field measurement data based on the field measurement signal.

[0025] Furthermore, the signal conversion device is two wireless communication devices, or the signal conversion device is an electric slip ring, wherein the wires connecting the fixed structure and the rotating structure of the electric slip ring are the first data receiving and transmitting end and the second data receiving and transmitting end of the electric slip ring.

[0026] Furthermore, one end of the first signal coupling device is connected to the main controller of the top drive via a first fieldbus.

[0027] Furthermore, one end of the second signal coupling device is connected to the distributed substation via a second fieldbus.

[0028] The technical solution of the top-drive communication method of the present invention is as follows:

[0029] The first signal coupling device receives the control signal corresponding to the control command issued by the main controller, couples the control signal into the power transmission cable, and sends it to the second signal coupling device;

[0030] The second signal coupling device receives the control signal and sends the control signal to the top drive in sequence through the distributed substation and the signal conversion device, so that the top drive obtains the control command according to the control signal and executes it;

[0031] The signal conversion device includes a first data receiving and transmitting end and a second data receiving and transmitting end that are mechanically separated from each other. The signal conversion device is connected to the communication cable between the top drive and the distributed substation of the top drive. One end of the first signal coupling device is connected to the main controller of the top drive, and the other end of the first signal coupling device is connected to the power transmission cable between the power supply in the power control room and the DC power supply used to directly supply power to the distributed substation. The two ends of the second signal coupling device are respectively connected to the power transmission cable and the distributed substation.

[0032] The beneficial effects of the top-drive communication method of the present invention are as follows:

[0033] On the one hand, by setting up a signal conversion device with a first data receiving and transmitting end and a second data receiving and transmitting end that are mechanically separated from each other, the signal transmission is uninterrupted during the rotation of the top drive rotary head, avoiding the situation where the line is torn due to the excessive rotation angle of the top drive rotary head. On the other hand, data communication is carried out through the existing power transmission cable, which does not require the re-layout of cables and signal lines, can transmit over long distances, is not easily damaged, and has low cost.

[0034] Based on the above scheme, the top-drive communication method of the present invention can be further improved as follows.

[0035] Furthermore, it also includes:

[0036] The second signal coupling device receives the field measurement signal sent by the distributed substation, couples the field measurement signal into the power transmission cable between the power supply in the power control room and the DC power supply used to directly supply power to the top drive, and sends it to the first signal coupling device. The top drive generates the field measurement signal corresponding to the field measurement data and sends it to the distributed substation through the signal conversion device.

[0037] The first signal coupling device receives and sends the field measurement signal to the main controller, so that the main controller can obtain the field measurement data based on the field measurement signal.

[0038] Furthermore, the signal conversion device can be two wireless communication devices, or the signal conversion device can be an electric slip ring, wherein the fixed structure and the rotating structure of the electric slip ring are the first data receiving and transmitting end and the second data receiving and transmitting end of the electric slip ring.

[0039] Furthermore, one end of the first signal coupling device is connected to the main controller of the top drive via a first fieldbus.

[0040] Furthermore, one end of the second signal coupling device is connected to the distributed substation via a second fieldbus. Attached Figure Description

[0041] Figure 1 This is a schematic diagram of the structure of a top-drive communication system according to an embodiment of the present invention;

[0042] Figure 2 This is a flowchart illustrating a top-drive communication method according to an embodiment of the present invention.

[0043] The attached diagram lists the components represented by each number as follows:

[0044] 1. Electrical control room; 2. Main controller; 3. First fieldbus; 4. First signal coupling device; 5. Power supply; 6. First cable; 7. Second cable; 8. Top drive body box; 9. Second signal coupling device; 10. DC power supply; 11. Distributed substation; 12. Second fieldbus; 13. Third cable; 14. Fourth cable; 15. Fifth cable; 16. Signal conversion device; 17. Static terminal; 18. Moving terminal; 19. Sensor; 20. Electronic actuator; 21. Seventh cable; 22. Eighth cable. Detailed Implementation

[0045] like Figure 1 As shown, a top drive communication system according to an embodiment of the present invention includes a first signal coupling device 4, a second signal coupling device 9, and a signal conversion device 16 having a first data receiving and transmitting end and a second data receiving and transmitting end, wherein the first data receiving and transmitting end and the second data receiving and transmitting end are mechanically separated from each other. The signal conversion device 16 is used to connect to the communication cable between the top drive and the distributed substation 11 of the top drive. One end of the first signal coupling device 4 is connected to the main controller 2 of the top drive, and the other end of the first signal coupling device 4 is connected to the power transmission cable between the power supply 5 in the power control room 1 and the DC power supply 10 used to directly supply power to the top drive. The two ends of the second signal coupling device 9 are respectively connected to the power transmission cable and the distributed substation 11.

[0046] The first signal coupling device 4 receives the control signal corresponding to the control command issued by the main controller 2, and couples the control signal into the power transmission cable and sends it to the second signal coupling device 9;

[0047] The second signal coupling device 9 receives the control signal and sends the control signal to the top drive in sequence through the distributed substation 11 and the signal conversion device 16, so that the top drive can obtain control instructions and execute them according to the control signal. Specifically, the second signal coupling device 9 receives the control signal and sends the control signal to the top drive in sequence through the first data receiving and sending end and the second data receiving and sending end of the distributed substation 11 and the signal conversion device 16.

[0048] The first data receiving and transmitting end is installed on the top drive rotary head of the top drive, and the second data receiving and transmitting end is installed on a fixed component of the top drive, such as the housing or inner sleeve. Alternatively, the second data receiving and transmitting end is installed on the top drive rotary head of the top drive, and the first data receiving and transmitting end is installed on a fixed component of the top drive, such as the housing or inner sleeve. In this way, the signal transmission is not interrupted during the rotation of the top drive rotary head, and the situation of the circuit being torn due to excessive rotation angle of the top drive rotary head is avoided.

[0049] Specifically, the communication cables between the top drive and the distributed substations of the top drive include: the communication cables between the top drive rotary head of the top drive and the sensors or electronic actuators on the components that move together with the top drive rotary head and the distributed substations.

[0050] Specifically, the second signal coupling device 9 receives the control signal and sends it sequentially to the top drive via the distributed substation 11 and the signal conversion device 16, as follows:

[0051] The second signal coupling device 11 receives the control signal and sequentially transmits it through the distributed substation 11 and the signal conversion device 16 to the top drive rotary head of the top drive or the electronic actuator on a component moving together with the top drive rotary head. The signal conversion device 16 can be two wireless communication devices, or it can be an electric slip ring, wherein the fixed structure and the rotating structure of the electric slip ring constitute the first and second data receiving and transmitting ends of the slip ring. Specifically:

[0052] 1) When the signal conversion device 16 consists of two wireless communication devices, a wireless communication device is a device that uses electromagnetic waves to communicate without passing through conductors or cables. According to its purpose, it can be divided into a transmitter and a receiver; a single device can also function as both a transmitter and a receiver. In this embodiment, two wireless devices with transmit and receive functions are used to form the signal conversion device 16 of this patent. One wireless communication device serves as the first data receiving and transmitting end, and the other as the second data receiving and transmitting end. Specifically, the first wireless communication device serves as the first data receiving and transmitting end, and the second wireless communication device serves as the second data receiving and transmitting end. The first wireless communication device is fixed to the body of the top drive; that is, the first wireless communication device is the stationary terminal 17 in this invention. The second wireless communication device, fixed to the rotary head or its auxiliary structure, is the moving terminal 18 in this invention. Several sensors 19 and electronic actuators 20 are arranged on the top drive rotary head, respectively connected to the second wireless communication device, i.e., the moving terminal 18. The first wireless communication device, i.e., the stationary terminal 17, is connected to the distributed substation 11 using a wire, i.e., the eighth cable 22. The signal conversion device 16, composed of the second and first wireless communication devices, encodes and decodes the field measurement signals from the sensor 19 before transmitting them to the main controller 2. Control commands from the main controller 2 are also processed by the signal conversion device 16 before reaching the electronic actuator 20. Since there is no cable connection between the first and second wireless communication devices, there is no cable restricting the rotation of the rotary head, ensuring uninterrupted signal transmission during rotation. A battery pack or generator is installed on the rotary head to power the second wireless communication device mounted on the top-drive rotary head.

[0053] 2) The signal conversion device 16 is an electric slip ring. An electric slip ring is an electrical component responsible for connecting and transmitting energy and signals to a rotating body. It mainly consists of two parts: a rotating structure and a stationary structure (i.e., a fixed structure). The rotating structure connects to the top drive's rotary head and rotates with it; this is called the "rotor" or "moving ring," and it is generally connected to terminal electrical components. The stationary part connects to the fixed structure of the equipment; this is called the "stator" or "stationary ring," and it is generally connected to the power supply 5 or signal source. The slip ring as a whole relies on the principles of elastic overlap, rolling overlap, or sealing, as well as the design of the moving and sealing structures, precise component manufacturing, and appropriate material selection to form a stable and reliable rotating communication system. In the method of this patent, the stator (fixed structure) of the slip ring is the stationary terminal 17, and the rotor (rotating structure) is the moving terminal 18. Several sensors 19 and electronic actuators 20 are arranged on the top drive rotary head, respectively connected to the "rotor" of the slip ring, and then connected to the terminal of the distributed substation 11 from the terminal of the "stator" after passing through the slip ring. When the sensor 19 and the electronic actuator 20 rotate with the rotary head, the cables of the sensor 19 and the electronic actuator 20 will not become tangled in the equipment due to the action of the slip rings. Through the communication system and method of this invention, communication between the main controller 2 and the sensor 19 and the electronic actuator 20 is achieved.

[0054] On the one hand, by setting up a signal conversion device 16 with a first data receiving and transmitting end and a second data receiving and transmitting end that are mechanically separated from each other, the signal transmission is uninterrupted during the rotation of the top drive rotary head, avoiding the situation where the line is torn due to excessive rotation angle of the rotary head. On the other hand, data communication is carried out through the existing power transmission cable, which does not require the re-layout of cables and signal lines, can transmit over long distances, and is not easily damaged.

[0055] Optionally, in the above technical solution, the second signal coupling device 9 receives the field measurement signal sent by the distributed substation 11, couples the field measurement signal into the power supply 5 in the power control room 1 and the DC power supply 10 used to directly supply power to the top drive, and sends it to the first signal coupling device 4. The top drive generates the field measurement signal corresponding to the field measurement data and sends it to the distributed substation 11 through the signal conversion device 16.

[0056] The first signal coupling device 4 receives and sends the field measurement signal to the main controller 2, so that the main controller 2 can obtain the field measurement data based on the field measurement signal.

[0057] Specifically, the field measurement signal corresponding to the field measurement data generated by the top drive is generated by the sensor on the top drive rotary head or the component that moves together with the top drive rotary head.

[0058] Optionally, in the above technical solution, one end of the first signal coupling device 4 is connected to the main controller 2 of the top drive via the first fieldbus 3. Therefore:

[0059] 1) The main controller 2 sends control signals to the first signal coupling device 4 via the first fieldbus 3;

[0060] 2) The first signal coupling device 4 receives and sends the field measurement signal to the main controller 2 through the first fieldbus 3.

[0061] Optionally, in the above technical solution, one end of the second signal coupling device 9 is connected to the distributed substation 11 via the second fieldbus 12. Therefore:

[0062] 1) The second signal coupling device 9 sends control signals to the distributed substation 11 through the second fieldbus 12;

[0063] 2) Distributed substation 11 sends field measurement signals to the second signal coupling device 9 via the second fieldbus 12.

[0064] The following detailed description of a top-drive communication system of the present invention is provided through a complete embodiment. Specifically:

[0065] The main controller 2, power supply 5, and first signal coupling device 4 are located in the electrical control room 1. The main controller 2 and the first signal coupling device 4 are connected via a first fieldbus 3. The DC power supply 10 is located in the top drive body box 8. The power transmission cable between the power supply 5 and the DC power supply 10 used to directly supply power to the top drive includes a second cable 7, a fifth cable 15, a third cable 13, and a fourth cable 14. That is, the existing power transmission cable between the power supply 5 and the DC power supply 11 in the top drive is improved to obtain the power transmission cable of the present invention, which includes the second cable 7, the fifth cable 15, the third cable 13, and the fourth cable 14. Data communication is performed using the existing power transmission cable, which eliminates the need to rearrange cables and signal lines, enables long-distance transmission, is less prone to damage, and has low cost.

[0066] Power supply 5 is connected sequentially via second cable 7, fifth cable 15, and third cable 13. First signal coupling device 4 is connected via first cable 6 to the junction of second cable 7 and fifth cable 15. Second signal coupling device 9 is connected between fifth cable 15 and third cable 13. The top drive chassis 8 also includes a distributed substation 11. Distributed substation 11 is connected to the second signal coupling device 9 via a second fieldbus 12. DC power supply 10 supplies power to distributed substation 11 via fourth cable 14. Distributed substation 11 is connected to the first data receiving and transmitting end of signal conversion device 16 via eighth cable 22. The second data receiving and transmitting end of signal conversion device 16 is connected to the sensor 19 of the top drive and the electronic actuator 20 of the top drive via seventh cable 21. The communication cable between the top drive and its distributed substation 11 includes eighth cable 22 and seventh cable 21. Therefore:

[0067] 1) The process of sending control commands to the top drive includes:

[0068] The main controller 2 issues control commands, which are sequentially transmitted to the top drive via the first fieldbus 3, the first signal coupling device 4, the first cable 6, the second cable 7, the fifth cable 15, the second signal coupling device 9, the second fieldbus 12, the distributed substation 11, the eighth cable 22, the first data receiving and transmitting end, the second data receiving and transmitting end, and the seventh cable 21. The top drive controls the corresponding electronic actuators 20 to perform the corresponding functions according to the control commands.

[0069] 2) The process of returning field measurement data to the main controller 2 includes:

[0070] The sensor 19 of the top drive transmits the field measurement data sequentially to the main controller 2 through the seventh cable 21, the second data receiving and transmitting end, the first data receiving and transmitting end, the eighth cable 22, the distributed substation 11, the second fieldbus 12, the second signal coupling device 9, the fifth cable 15, the second cable 7, the first cable 6, the first signal coupling device 4, and the first fieldbus 3.

[0071] The top-drive communication system of the present invention has the following characteristics:

[0072] 1) The communication signal between the main controller 2 and the distributed substation 11 is transmitted on the power supply cable of the distributed substation 11.

[0073] 2) The main controller 2, the first signal coupling device 4, and the power supply 5 are all located inside the electrical control room 1. The main controller 2 and the first signal coupling device 4 communicate through the first fieldbus 3.

[0074] 3) The second signal coupling device 9, DC power supply 10, and distributed substation 11 are placed inside the top drive body box 8 located on the top drive body. The second signal coupling device 9 and the distributed substation 11 communicate via the second fieldbus 12;

[0075] 4) The input terminal of the DC power supply 10 is connected to the power supply 5 located in the electrical control room 1 via a second cable 7 that is hundreds of meters long, thus achieving the function of drawing power. The output terminal of the DC power supply 10 supplies power to the second signal coupling device 9 and the distributed substation 11 via a third cable 13 and a fourth cable 14, thereby realizing the power supply for the electrical components on the top drive body.

[0076] 5) Signal transmission mainly refers to the transmission of signals on the second cable 7 via a signal coupling device. The function of the signal coupling device is to convert the signals transmitted from the fieldbus, couple them onto the power line cable, and then decode the signals through another signal coupling device. In this invention, the first signal coupling device 4 and the second signal coupling device 9 are connected in parallel with the second cable 7 via the first cable 6 and the sixth cable, respectively. The first signal coupling device 4 and the second signal coupling device 9 can convert the information transmitted from the fieldbus into signals for transmission and decoding on the second cable 7, realizing communication between the main controller 2 and the distributed substation 11. This is fundamentally different from the existing technology of transmitting signals via optical fiber or network cable, and overcomes the disadvantage of optical fiber communication being easily damaged.

[0077] 6) In existing top drives, the sensors 19 and electronic actuators 20 are generally directly connected to the terminals of the distributed substation 11 or directly connected to the main controller 2 via a multi-core cable after being converted through terminals on the main body. In this invention, the sensors 19 and electronic actuators 20 are connected to the distributed substation 11 after being processed by the signal conversion device 16. The signal conversion device 16 includes a stationary terminal 17 and a moving terminal 18, which can be relatively stationary or moving relative to each other, but can transmit signals and electrical energy between them through brushes, electromagnetic waves, radio waves, etc. The stationary terminal 17 is connected to the distributed substation 11 through the eighth cable 22, and the moving terminal 18 is connected to the sensors 19 and electronic actuators 20 through the seventh cable 21. The function of this device is to ensure communication with the distributed substation 11 when the sensors 19 and electronic actuators 20 rotate with the top drive's rotary head, without changing the length and arrangement of the seventh cable 21 and the eighth cable 22.

[0078] 7) Generally, the stationary terminal 17 is fixed to a stationary component of the top drive body, such as the top drive housing or guardrail. The moving terminal 18 is fixed to the top drive rotary head or a component that moves with it, such as the top drive's mounting arm or back clamp.

[0079] This invention provides a new communication system for top-drive communication, which has the following beneficial effects:

[0080] 1) This system boasts high reliability, low latency, and convenient maintenance. It utilizes the power cable 5, which powers the distributed substations 11 within the main unit via a traditional top drive, to transmit communication signals. Compared to traditional top drive fiber optic communication methods, this approach offers higher reliability, longer transmission distance, less susceptibility to damage, lower maintenance difficulty, and lower maintenance costs. Compared to traditional multi-core cable transmission schemes, it requires fewer cable cores, eliminates the need to increase the number of cable cores when expanding communication channels, and offers better scalability. Addressing the issue of communication lines being unable to be directly connected due to the rotation of the rotary head between the sensors 19 and electronic actuators 20 (which move with the rotary head) and the distributed substations 11 within the main unit, this invention proposes a method using a signal conversion device 16 to relay signals. This ensures that the lines between the sensors 19 or electronic actuators 20 and the distributed substations 11 are unaffected by the rotational motion of the rotary head. This guarantees signal and power transmission without affecting the rotational motion of the top drive rotary head.

[0081] 2) Primarily used for signal transmission between the top drive main controller 2 and the sensors 19 and electronic actuators 20 on the top drive body. This communication system and method achieves stable signal transmission between the sensors 19, electronic actuators 20, and the distributed substations 11 within the main station during the rotation of the rotary head, and solves many problems of traditional communication schemes between the main controller 2 and the distributed substations 11. Compared with existing multi-core cable schemes, this system has rich scalability and does not limit the number of transmitted signals without modifying the communication cable bundle hardware. Compared with fiber optic communication schemes, it has better stability, higher reliability, less mechanical damage, and better environmental adaptability. Even in the event of accidental damage, its repair difficulty and cost are lower than those of fiber optics. The signal transmission method of the sensors 19 and electronic actuators 20 moving with the rotary head proposed in this invention fills the current technical gap in top drive signal transmission. This invention is applicable to various types and models of top drives, providing a high-speed and reliable communication system for the transmission of various control signals and status signals, laying a solid foundation for the informatization and intelligent upgrading of top drives.

[0082] 3) This invention addresses the problem of communication lines being unable to be directly connected due to the rotation of the rotary head during signal acquisition and control signal transmission in the top drive device. This occurs when the electronic actuator 20, which moves with the rotary head, communicates with the distributed substation 11 within the main unit. The invention proposes a method and general principles for transmitting signals that rotate with the rotary head. It also addresses practical problems encountered in multi-core cable communication or fieldbus communication between the main unit and the main controller 2, designing a method to couple signals to the power supply line 5, thus achieving long-distance and reliable signal transmission.

[0083] like Figure 2 As shown, a top-drive communication method according to an embodiment of the present invention includes the following steps:

[0084] S1. The first signal coupling device 4 receives the control signal corresponding to the control command issued by the main controller 2, and couples the control signal into the power transmission cable and sends it to the second signal coupling device 9.

[0085] S2. The second signal coupling device 9 receives the control signal and sends the control signal to the top drive in sequence through the distributed substation 11 and the signal conversion device 16, so that the top drive can obtain control commands and execute them according to the control signals.

[0086] The signal conversion device 16 includes a first data receiving and transmitting end and a second data receiving and transmitting end that are mechanically separated from each other. The signal conversion device 16 is connected to the communication cable between the top drive and the distributed substation 11 of the top drive. One end of the first signal coupling device 4 is connected to the main controller 2 of the top drive, and the other end of the first signal coupling device 4 is connected to the power transmission cable between the power supply 5 in the power control room 1 and the DC power supply 10 used to directly supply power to the distributed substation 11. The two ends of the second signal coupling device 9 are respectively connected to the power transmission cable and the distributed substation 11.

[0087] On the one hand, by setting up a signal conversion device 16 with a first data receiving and transmitting end and a second data receiving and transmitting end that are mechanically separated from each other, the function of uninterrupted signal transmission during the rotation of the top drive rotary head is realized, avoiding the situation where the line is torn due to excessive rotation angle of the top drive rotary head. On the other hand, data communication is carried out through existing power transmission cables, which does not require re-laying cables and signal lines, can transmit over long distances, is not easily damaged, and has low cost.

[0088] Optionally, the above technical solution also includes:

[0089] S3. The second signal coupling device 9 receives the field measurement signal sent by the distributed substation 11 and couples the field measurement signal into the power transmission cable between the power supply 5 in the power control room 1 and the DC power supply 10 used to directly supply power to the top drive, and sends it to the first signal coupling device 4. The top drive generates the field measurement signal corresponding to the field measurement data and sends it to the distributed substation 11 through the signal conversion device 16.

[0090] S4. The first signal coupling device 4 receives and sends the field measurement signal to the main controller 2, so that the main controller 2 can obtain the field measurement data based on the field measurement signal.

[0091] Optionally, in the above technical solution, the signal conversion device 16 is a wireless communication device or an electric slip ring, wherein the fixed structure and the rotating structure of the electric slip ring are the first data receiving and transmitting end and the second data receiving and transmitting end of the electric slip ring.

[0092] Optionally, in the above technical solution, one end of the first signal coupling device 4 is connected to the main controller 2 of the top drive via the first fieldbus 3.

[0093] Optionally, in the above technical solution, one end of the second signal coupling device 9 is connected to the distributed substation 11 via the second fieldbus 12.

[0094] In the above embodiments, although the steps are numbered S1, S2, etc., they are only specific embodiments given in this application. Those skilled in the art can adjust the execution order of S1, S2, etc. according to the actual situation, which is also within the protection scope of this invention. It can be understood that in some embodiments, some or all of the above embodiments may be included.

[0095] The implementation of each step in the top drive communication method of the present invention described above can be referred to the content of the embodiment of the top drive communication system described above, and will not be repeated here.

[0096] In 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 at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0097] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0098] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A top-drive communication system, characterized in that, The device includes a first signal coupling device, a second signal coupling device, and a signal conversion device with a first data receiving and transmitting end and a second data receiving and transmitting end, wherein the first data receiving and transmitting end and the second data receiving and transmitting end are mechanically separated from each other. The signal conversion device is used to connect to the communication cable between the top drive and the distributed substation of the top drive. One end of the first signal coupling device is connected to the main controller of the top drive, and the other end of the first signal coupling device is connected to the power transmission cable between the power supply in the power control room and the DC power supply used to directly supply power to the distributed substation. The two ends of the second signal coupling device are respectively connected to the power transmission cable and the distributed substation. The first signal coupling device receives the control signal corresponding to the control command issued by the main controller, couples the control signal into the power transmission cable, and sends it to the second signal coupling device; The second signal coupling device receives the control signal and sends the control signal sequentially through the distributed substation and the signal conversion device to the top drive, so that the top drive obtains the control command according to the control signal and executes it; The second signal coupling device receives the field measurement signal sent by the distributed substation, couples the field measurement signal into the power transmission cable between the power supply in the power control room and the DC power supply used to directly supply power to the top drive, and sends it to the first signal coupling device. The top drive generates the field measurement signal corresponding to the field measurement data and sends it to the distributed substation through the signal conversion device. Specifically, the field measurement signal corresponding to the field measurement data generated by the top drive is generated by the sensor on the top drive rotary head or the component that moves together with the top drive rotary head. The first signal coupling device receives and sends the field measurement signal to the main controller, so that the main controller obtains the field measurement data based on the field measurement signal; The signal conversion device is two wireless communication devices, or the signal conversion device is an electric slip ring, wherein the wires connecting the fixed structure and the rotating structure of the electric slip ring are the first data receiving and transmitting end and the second data receiving and transmitting end of the electric slip ring, respectively. When the signal conversion device is two wireless communication devices, one wireless communication device is used as the first data receiving and transmitting end, and the other is used as the second data receiving and transmitting end. Specifically, the first wireless communication device is used as the first data receiving and transmitting end, and the second wireless communication device is used as the second data receiving and transmitting end. The first wireless communication device is fixed on the body of the top drive. Several sensors and electronic actuators are arranged on the top drive slewing head, which are respectively connected to the second wireless communication device. The first wireless communication device is connected to the distributed substation via the eighth cable. The signal conversion device composed of the second wireless communication device and the first wireless communication device encodes and decodes the field measurement signals of the sensors and transmits them to the main controller. The control commands of the main controller are processed by the signal conversion device and then reach the electronic actuators. One end of the first signal coupling device is connected to the main controller of the top drive via a first fieldbus; One end of the second signal coupling device is connected to the distributed substation via a second fieldbus.

2. A top-drive communication method, characterized in that, include: The first signal coupling device receives the control signal corresponding to the control command issued by the main controller, couples the control signal into the power transmission cable, and sends it to the second signal coupling device; The second signal coupling device receives the control signal and sends the control signal to the top drive in sequence through the distributed substation and the signal conversion device, so that the top drive obtains the control command according to the control signal and executes it; The signal conversion device includes a first data receiving and transmitting end and a second data receiving and transmitting end that are mechanically separated from each other. The signal conversion device is connected to the communication cable between the top drive and the distributed substation of the top drive. One end of the first signal coupling device is connected to the main controller of the top drive, and the other end of the first signal coupling device is connected to the power supply in the power control room and the power transmission cable for direct supply to the distributed substation. The two ends of the second signal coupling device are respectively connected to the power transmission cable and the distributed substation. Also includes: The second signal coupling device receives the field measurement signal sent by the distributed substation, couples the field measurement signal into the power transmission cable between the power supply in the power control room and the DC power supply used to directly supply power to the top drive, and sends it to the first signal coupling device. The top drive generates the field measurement signal corresponding to the field measurement data and sends it to the distributed substation through the signal conversion device. Specifically, the field measurement signal corresponding to the field measurement data generated by the top drive is generated by the sensor on the top drive rotary head or the component that moves together with the top drive rotary head. The first signal coupling device receives and sends the field measurement signal to the main controller, so that the main controller obtains the field measurement data based on the field measurement signal; The signal conversion device is two wireless communication devices, or the signal conversion device is an electric slip ring, wherein the fixed structure and the rotating structure of the electric slip ring are the first data receiving and transmitting end and the second data receiving and transmitting end of the electric slip ring; When the signal conversion device is two wireless communication devices, one wireless communication device is used as the first data receiving and transmitting end, and the other is used as the second data receiving and transmitting end. Specifically, the first wireless communication device is used as the first data receiving and transmitting end, and the second wireless communication device is used as the second data receiving and transmitting end. The first wireless communication device is fixed on the body of the top drive. Several sensors and electronic actuators are arranged on the top drive slewing head, which are respectively connected to the second wireless communication device. The first wireless communication device is connected to the distributed substation via the eighth cable. The signal conversion device composed of the second wireless communication device and the first wireless communication device encodes and decodes the field measurement signals of the sensors and transmits them to the main controller. The control commands of the main controller are processed by the signal conversion device and then reach the electronic actuators. One end of the first signal coupling device is connected to the main controller of the top drive via a first fieldbus; One end of the second signal coupling device is connected to the distributed substation via a second fieldbus.

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